SMS Siemag AG - Alu-web.de

© Achenbach SMS Meer
Special: aluminium
rolling Special: industry aluminium
extrusion industry
achenbach scored with
Hybrex integrated – an technology innovative
press technology through
radical High-speed new slitters approaches
demand sophisticated
iaS: measuring ideal conditions techniques
for further growth
Danieli aluminium
iST Technology: Forum Modernisation
of existing melting
2013
plants clean, low-cost – an alternative
to reduction new investments technologies
on the horizon
is the lMe distorting
instead current of picture making of the referencmary
market aluminium prices?
pri-
industry
10 11
Volume 89 89 · · November October 2013
International Journal for Industry, Research and Application

BATCH HOMOGENIZING PLANTS
FOR FLEXIBLE HEAT TREATMENT
ecoplants
Hertwich Engineering supplies innovative
solutions for the production and process -
ing of aluminium billets. The newly developed
batch homogenizing plant is yet
further evidence of this: The furnace is
designed for extra fast heating of logs.
Due to the reversing air concept and regulation
by flaps, some 20 % faster heating is
achieved as well as improved temperature
uniformity. Energy consumption is re duced
accordingly, which is why the batch homogenizing
plant was awarded the ecoplants
mark as a particularly sustainable solution
from Hertwich.
Hertwich Engineering is a one-stop
supplier for state-of-the-art aluminium
casthouses. We offer customer-focussed
service throughout your project and beyond
- for the lifetime of the machine.
Within the SMS group, Hertwich is part of
the SMS Meer Business Area, a leading
international company in heavy machinery
and plant engineering.
www.hertwich.com
Batch homogenizing furnace
Open-air rolling ingot storage facility
Stack of extrusion billets

editorial
Volker Karow
Chefredakteur
Editor in Chief
im nächsten Jahr
wird alles besser
it will all be
better next year
Die Weltwirtschaft ist im ersten Halbjahr
2013 nur verhalten gewachsen. Der Internationale
Währungsfonds (IWF) veröffentlichte
für diesen Zeitraum jüngst Wachstumsraten
von 2,5 Prozent; dies entspricht der verhaltenen
Dynamik im zweiten Halbjahr 2012.
Während die hoch entwickelten Volkswirtschaften
sich etwas stabilisiert haben, hat sich
das Tempo der aufstrebenden Länder verlangsamt,
doch bleiben sie die Haupttreiber
der weltwirtschaftlichen Entwicklung. Für das
Gesamtjahr 2013 rechnet der IWF mit einem
globalen Wachstum von 2,9 Prozent, während
das Wachstum der „Emerging Market
and Developing Economies“ bei 4,5 Prozent
liegen wird. Im nächsten Jahr soll alles besser
werden. Dann werde die Weltwirtschaft laut
IWF-Projektion um 0,7 Prozentpunkte zulegen
und auch die etablierten Industrieländer
einen Gang höher schalten.
Diese Einschätzung deckt sich mit jüngsten
Konjunkturprognosen von europäischen und
deutschen Instituten und Branchenverbänden.
Der deutsche Maschinen- und Anlagenbau,
neben der Automobilbranche das Flagschiff
der deutschen Industrie, rechnet für 2014
mit einem Wachstum von real drei Prozent –
nach rückläufigen Produktionszahlen dieses
Jahr, die am Jahresende voraussichtlich bei
minus einem Prozent liegen werden. Die für
Deutschland wichtigen Exportmärkte China
und USA ziehen derzeit jedoch wieder an
und auch in Europa scheint die rezessive Phase
weitgehend abgeschlossen zu sein, so der
Verband der Maschinenbauer.
China hat seine Schwächephase offenbar
überwunden, das Konjunkturpaket der Zentralregierung
scheint zu wirken. Nach sechs
langsameren Monaten in Folge hat die zweitgrößte
Volkswirtschaft der Welt mit einem
Wachstum von 7,8 Prozent im dritten Quartal
wieder deutlich Fahrt aufgenommen. China
könnte damit wieder in die Rolle des wichtigen
Impulsgebers der Weltwirtschaft schlüpfen.
Die Aluminiumindustrie ist seit geraumer
Zeit von zwei eher gegenläufigen Entwicklungen
geprägt: Die anhaltend niedrigen Metallnotierungen
zwingen große internationale
Produzenten vermehrt zu Produktionskürzungen
und Stilllegungen von Hüttenkapazitäten;
kleine, veraltete Betriebe in Osteuropa,
wie KAP und Aluminij Mostar, stehen sogar
vor der Pleite. Dieser Trend wird die globale
Kostenkurve der Aluminiumerzeugung
nachhaltig absenken. Im Walzsektor werden
dagegen von den großen Halbzeugherstellern
massiv Kapazitäten aufgebaut, um in den
kommenden Jahren die stark wachsende
Nachfrage nach Blechanwendungen für die
nächste Fahrzeuggeneration zu befriedigen.
The global economy only recorded modest
growth in the first half of 2013. The International
Monetary Fund (IMF) recently published
a figure of 2.5 percent for growth during
this period, and this corresponds to the
modest growth in the second half of 2012.
Although growth was somewhat stable in
the advanced economies, it weakened in the
emerging countries, even though these still remain
the main driving forces for global development.
The IMF is expecting global growth of
2.9 percent for the whole of 2013, with growth
of 4.5 percent in the so-called ‘emerging markets
and developing economies’. Things should
be better next year. The IMF then forecasts
growth of 0.7 percentage points in the global
economy and even the economies in the established
industrialised nations are expected
to move up a gear.
This assessment is in line with most economic
forecasts issued by European and German
institutes and trade associations. The
German mechanical and plant engineering
sector, which together with the car industry is
the flagship of German economy, is expecting
growth in real terms of three percent in 2014
– following a decline in production this year
that is expected to manifest itself in a fall of
one percent for the year as a whole. According
to the German engineering association,
China and USA, which are the important
export markets for Germany, are currently
picking up, though, and the recessionary phase
in Europe also appears to be coming to an
end.
China appears to have overcome its weak
phase and the package to stimulate the economy
introduced by the central government
seems to be working. After six consecutive
months of slower growth, the world’s second
largest economy has once again gathered
speed significantly, with growth of 7.8 percent
in the third quarter. China could thus
once again take on the role as the global economy’s
most important stimulator.
For some time, the aluminium industry
has been affected by two somewhat opposing
developments. On the one hand, persistently
low metal prices are increasingly forcing large
international producers to cut production and
close smelters; small out-dated plants in Eastern
Europe, such as KAP and Aluminij Mostar,
are even on the brink of bankruptcy. This
trend will enduringly lower the global cost
curve for aluminium production even further.
In contrast, the major semis producers are
undertaking massive increases in capacity in
the rolling sector in order to satisfy strongly
increasing demand for sheet for the next generation
of vehicles in the years ahead.
ALUMINIUM · 11/2013

inhalt
editorial
Im nächsten Jahr wird alles besser • It will all be better next year .......
aKtuelles • news in Brief
Voerdal gerettet .......................................................................... 6
Erfolg bei der Energiewende erfordert EEG-Reform ............................ 6
European Aluminium Congress around the corner .............................. 7
14
CPT and Continuus-Properzi form joint venture for rod lines ................ 7
Alcoa surprises with strong Q3 performance ..................................... 8
Senaat and Ducab in joint Abu Dhabi aluminium rod venture .............. 8
wirtsChaft • eConomiCs
Al-Preise / Produktionsdaten der deutschen Aluminiumindustrie .....10/12
Trimet baut Automotive-Bereich aus und erschließt
neue Geschäftsfelder • Trimet extends its automotive
sector and develops new business fields .........................................14
Current picture of the primary aluminium industry ............................18
8
In the limelight – the Arabal Conference 2013 ................................ 24
aluminiumwalzindustrie
aluminium rolling industry
Rusal – largest producer of aluminium foil in Russia ........................ 26
KunShan Aluminium erhöht 6-µm-Folienproduktion auf 40.000
Jahrestonnen – Achenbach punktet mit integrativer Technologie
KunShan Aluminium increases 6 µm foil production to 40.000 tpy –
Achenbach scores with integrated technology ................................. 28
46
The Royal Mint: Siemens VAI implements optimal
upgrade path for the legacy automatic gauge control ...................... 2
Kobe Steel to set up factory in China for aluminium sheet .................6
Hochgeschwindigkeitsschneidanlagen erfordern anspruchsvolle Messtechnik
• High-speed slitters demand sophisticated measuring techniques 8
3 rd Global Aluminium Foil Roller Conference on the horizon ...............45
Alro commissions new cold finishing lines supplied by Salico .............46
Neue Schneidpräzision für Karosseriebleche aus Aluminium
New edge in precision cutting of body sheet ...................................48
Installation of UACJ cold-rolling mill for Thailand in final stage .........49
54
Energy Advisor von SMS Siemag: Energieströme transparent
machen und Energieverbrauch senken • The SMS Siemag Energy
Advisor: Making energy flows transparent, cutting consumption ........ 50
latest news
www.alu-web.de
Danieli Aluminium Technology Forum 2013:
Latest breakthrough technology in industrial operation .......................54
teChnologie • teChnology
Clean, low-cost reduction technologies on the horizon .......................57
4 ALUMINIUM · 11/2013

Contents
Advanced casting research to boost auto industry production ..............59
Maschinenfabrik Eirich feiert 150-jähriges Jubiläum ............................60
a nwendung • appliC ation
Ball Packaging bringt innovative Getränkedosen auf den Markt
Ball Packaging launches innovative beverage cans ............................61
Company n ews w orldwide
Aluminium smelting industry .........................................................62
On the move ..............................................................................64
Bauxite and alumina activities .......................................................65
Aluminium semis .........................................................................65
Suppliers ...................................................................................66
doCumentation
Patente .....................................................................................66
Vorschau • Preview .....................................................................82
Impressum • Imprint ....................................................................82
l ieferverzeiC hnis • s uppliers d ireC tory .............68
inserenten dieser ausgabe
list of advertisers
ABB AB, Sweden 27
August Mössner
GmbH & Co. KG, Germany 31
Aumund Fördertechnik GmbH, Germany 15
Beta LaserMike, Germany 23
Buss AG, Switzerland 17
Danieli Fröhling Josef Fröhling
GmbH & Co. KG, Germany 55
Didion International Inc., USA 19
Dubal Aluminium, UAE 13
Emirates Aluminium, UAE 11
Getriebebau Nord
GmbH & Co. KG, Germany 5
H+H H errmann + Hieber
GmbH, Germany 20, 52, 65
Hertwich Engineering GmbH, Austria 2
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany 22 , 49
Micro-Epsilon Messtechnik
GmbH & Co. KG, Germany 41
Mino SpA, Italy 25
Novelis PAE, France 51
Otto Junker GmbH, Germany 29
Salico Hispania S.A., Spain 37
Shanghai Jieru, PRC 43
Siemens Plc, UK 35
SMS Logistiksysteme GmbH, Germany 33
SMS Siemag, Germany 84
T.T. Tomorrow Technology SpA, Italy 21
NORD DRIVESYSTEMS | Intelligent Drivesystems, Worldwide Services
Robust, long-life geared motors
Gear Unit
Special Unicase housings
Robust housing material
GG20, optionally GGG40
Quadralip sealing with
material VITON to suit
high ambient temperatures
Optional labyrinth seal for
increased protection
Motors
Suitable for high
ambient temperatures
Roller table steel mill
duty motors with duty
cycles up to S9
Cast iron housing
material, absorbing
vibration and shocks
IC411 or IC410 cooling
metals.nord.com
Getriebebau NORD GmbH & Co. KG,
Tel: +49 (0) 45 32 / 289 - 0, info@nord.com
Member of the NORD DRIVESYSTEMS Group

Aktuelles
Aluflexpack übernimmt
schweizer Verpackungshersteller
für tiernahrung
Die Aluflexpack Gruppe, Teil der Industrieholding
Montana Tech Components AG,
übernimmt 85 Prozent der Schweizer Process
Point Service AG (PPS). Das Unternehmen
fertigt mit rund 30 Mitarbeitern flexible
Verpackungen aus Aluminium, vor allem für
Tiernahrung. PPS beliefert mit jährlich rund
4.500 Tonnen Aluverbundfolien den gesamten
europäischen Markt. Der Umsatz betrug
im vergangenen Jahr 31 Mio. Schweizer
Franken.
Die Aluflexpack-Gruppe ist mit einem
Marktanteil von etwa 70 Prozent die größte
Aluminium-Verpackungsgruppe in Kroatien
und die Nummer 3 in Europa. Der Hersteller
von flexiblen Aluverpackungen für Lebensmittel
und Tiernahrung, Milchprodukte und
Süßwaren beschäftigt rund 630 Mitarbeiter
in Kroatien, Polen, Österreich, Italien und
Deutschland. Der Hauptsitz der Gruppe befindet
sich in Zadar, Kroatien.
© H + H
Neuer Webauftritt von H+H präsentiert Intralogistik-lösungen
Der in Denkendorf bei Stuttgart ansässige
Logistikspezialist H + H Herrmann + Hieber
hat seine Homepage komplett neu gestaltet.
Der neue Auftritt findet sich unter www.
herrmannhieber.de.
Die neue Konzeption gibt dem Web-Besucher
einen detaillierten Überblick über das
Leistungsspektrum des Unternehmens: komplexe
Systemlösungen in den verschiedenen
Branchen, wichtige
Einzelkomponenten,
Modernisierungsmöglichkeiten
und Dienstleistungen
rund um das
Lieferprogramm.
Auf herausragende
Intralogistik-Lösungen
wird im
Rahmen von „Projekt-Berichten“
ausführlich
in Wort und
Bild eingegangen.
Intralogistik-Lösungen
in Unternehmen der Aluminium-
Halbzeugindustrie nehmen in der Präsentation
einen relativ breiten Raum ein. H+H hat
besonders den automatisierten Langguttransport
in Aluminium-Strangpresswerken wichtige
Impulse gegeben. Heute finden sich von
H+H konzipierte und installierte Anlagen in
nahezu allen wichtigen Presswerken Europas.
Personeller Wechsel an der
spitze der Aluminium-Messe
Markus M. Jessberger (52), seit 2008 Event
Director der Messen Aluminium, Composites
Europe und der Hybrid Expo, wird zum
Jahresende Reed Exhibitions Deutschland
verlassen um sich am Wohnort seiner Familie
in der Nähe von Nürnberg neuen beruflichen
Aufgaben zu stellen. Seine Nachfolge tritt
Michael Köhler (34) an, der seit 2008 Projektleiter
der Composites Europe ist und seit
2010 die Aluminium leitet.
Hans-Joachim Erbel, CEO von Reed Exhibitions
Deutschland, hob hervor, dass sich
die Aluminium-Messe unter der Leitung Jessbergers
sehr dynamisch entwickelt habe. Im
Zuge ihres Standortwechsels von Essen nach
Düsseldorf hatte die Aluminium 2012 einen
Ausstellerzuwachs von 15 Prozent, eine
zusätzliche Flächenbelegung von 20 Prozent
und ein Besucher-Plus von fast 25 Prozent
erzielt. Im Auslandsgeschäft setzte Jessberger
mit der Aluminium Brazil einen weiteren
Akzent in der Globalisierungsstrategie der
weltweit stattfindenden Aluminium-Messen.
Köhler leitet seit 2010 die Aluminium-
Messe und ist als Brand Manager für den
weltweiten Messezyklus der Aluminium in
Shanghai, Mumbai, Dubai und Sao Paulo
verantwortlich.
Voerdal gerettet
Die Aluminiumhütte Voerdal kann auch 2014
weiter produzieren. Das Insolvenzverfahren
soll bis März nächsten Jahres beendet werden.
Insolvenzverwalter Frank Kekebus teilte
der 300 Mann starken Belegschaft Mitte Oktober
mit, dass der Gläubigerausschuss seinen
Empfehlungen gefolgt sei. Er verwies darauf,
dass Voerdal dieses Jahr ein positives Ergebnis
verbuchen könne. Dennoch bleibt die Hütte
von schwierigen Rahmenbedingungen begleitet.
Die bisherige Befreiung von den Netzentgelten
wird es künftig nicht mehr geben. Welche
Belastung auf das Unternehmen zukommt,
ist derzeit noch unklar, doch könnte sie bis
zu zwei Millionen Euro betragen. Voerdal
hatte bereits im Mai 2012 Insolvenz angemeldet.
Mitte letzten Jahres hatte der Aluminiumkonzern
Aleris die Gießerei des Werks
übernommen und damit 130 Arbeitsplätze
gesichert.
erfolg bei der energiewende
erfordert eeG-Reform
Inzwischen ist es amtlich: Die EEG-Umlage
wird 2014 auf 6,24 Cent je Kilowattstunde
erhöht. Die WirtschaftsVereinigung Metalle
(WVM) sieht die Grenzen der Belastbarkeit
sowohl für private wie industrielle Verbraucher
längst erreicht. „Die Umlage finanziert
einen Systemfehler im Erneuerbare-Energien-
Gesetz (EEG), der einen ungesteuerten Ausbau
der Erneuerbaren Energien produziert
und damit die Versorgungssicherheit belastet.
Das senkt dauerhaft die Akzeptanz für die
Energiewende“, erklärt WVM-Präsident Oliver
Bell. Die Regierungsbildung wecke Erwartungen
auf wettbewerbsfähige Industriestrompreise,
einen Ausgleich zwischen Marktchancen
und Kosten der Klimapolitik, eine
Reform des EEG und eine tragfähige Umsetzung
der Energiewende.
Gefahr drohe aktuell durch die Eröffnung
eines Beihilfeverfahrens gegen die Besondere
Ausgleichsregelung im EEG. Die EU-
Kommission greife diese Ausgleichsregelung
gezielt an, um einen möglichst hohen Druck
auf die Bundesregierung auszuüben, das EEG
zu ändern. „Allein die schwebende Gefahr
einer Aussetzung der besonderen Ausgleichsregelung
würde die Wettbewerbsfähigkeit
stromintensiver Unternehmen mit mehreren
Hunderttausend Arbeitsplätzen in Deutschland
existenzgefährdend belasten. Die neue
Bundesregierung steht in der Verantwortung,
das EEG europakonformer zu gestalten und
zugleich die Entlastungen stromintensiver
Unternehmen zu verteidigen“, so Bell.
ALUMINIUM · 11/2013

NeW s IN B RIef
european Aluminium Congress around the corner
If not already done, register now – for
the European Aluminium Congress 2013.
On 25 and 26 November 2013 GDA, the
association of the aluminium industry in
Germany, will be organising the congress
“Aluminium Automotive Applications –
Tomorrow’s Design and Sustainable Performance”.
This year’s European Aluminium Congress
(EAC) will be a venue for industry experts in
lightweight construction from the automotive
and aluminium industries. Some 80 companies
with about 100 experts have already
registered in October: professionals from the
semis industry as well as automotive parts
suppliers and OEMs, such as Audi, BMW,
Daimler, Ford, Honda or Jaguar. Suppliers
from the area of plant construction or surface
engineering will also take part in the congress.
Apart from the various uses of aluminium in
vehicle manufacturing, further developments
that have potential to make vehicles of the
future even lighter and more energy efficient
will also be presented at the EAC 2013.
In his keynote address, Automotive – the
key market for the aluminium industry, GDA
president Heinz-Peter Schlüter will point out
that the use of aluminium in automobile still
shows excellent growth potential. Until 2030
the regulation of CO 2 emissions will translate
into billions in growth in the triple-digit range,
in the area of lightweight construction for automobiles.
Accordingly, by 2030 automobile
manufactures must raise from 30 to 70 percent
the proportion of lightweight parts in vehicles,
in order to compensate for the weight
increase in vehicles caused by electric drives
and fuel efficient engine technology. This will
create a new growth market for the aluminium
industry and its suppliers.
In his keynote address Body-in-White
Lightweight Design at Mercedes-Ben – Effects
on the Material and Assembly Concepts
by the example of the new S Class, Jürgen
Bösselman of the Daimler AG – Mercedes-
Benz Research and Development will show
the effects that lightweight body construction
has on material and manufacturing concepts at
Mercedes-Benz.
The EAC is divided into a total of five sessions,
dealing with the subjects design, auto
body, process technologies, joining technologies
and surfaces, as well as markets, recycling
and sustainability. Notable speakers from international
companies will give their insights
and provide real-life examples in all the sessions
of the congress. The official language of
the congress is English. All presentations will
be simultaneously translated into German.
eAA reinforces its
recycling expertise
The European Aluminium Association (EAA)
has appointed Magdalena Garczynska director
of its Recycling department. This new position
is to strengthen the association’s expertise on a
segment that is an environmental cornerstone
of the aluminium industry. The appointment
comes at a time when the EU starts to revise its
waste legislation. “We want the future waste
legislation to contribute to secure access to secondary
raw materials for the recycling industry,”
said Gerd Götz, EAA’s director general.
Ms Garczynska, a Polish national, has over
ten years’ experience in engineering and public
affairs. Prior to joining the EAA, she was
a technical manager at the European Association
of the Machine Tool Industries (Cecimo)
where she guided the association’s work on
environmental, energy and other issues. She
also worked at the NSF International and the
Berlin University of Technology. Magdalena
holds a M.Sc. degree in mechanical engineering
and a post-graduate degree in Fluid Dynamics.
The EAA has enlarged its membership to
recyclers that were previously represented by
the Organisation of the European Aluminium
Recycling Industry (OEA), and consequently
founded a new recycling department.
CPt and Continuus-Properzi form joint venture for rod lines
CPT, a Tunisian company managed by Italian
engineers, produces and sells continuous casting
and rolling lines for aluminium rod with
a potential production of 20,000 tonnes a
year or more. Earlier this year CPT and Continuus-Properzi
have signed a joint venture
agreement when second-hand Properzi lines
still demanded by the international market
Casting machine
completely disappeared by age or
became too expensive in refurbishing.
CPT now offers technical
solutions with European components
and proven technology that
bridges the gap between lower
level machinery and lines which
are designed for the maximum
level of automation, with a vast
number of options.
The lines from caster to coiler
(also with double automatic reels)
are offered under technical supervision
of Continuus-Properzi in
capacities of 1.6, 2.5 and 3.5 tph,
and are capable of producing E.C.
aluminium and 6201 T4 rod. These lines are
addressed to small cable makers who want
to produce their required aluminium rod inhouse.
These companies, generally located in
emerging countries, select those regions characterised
by low-cost labour with basic skills
Finishing mill
as strategic locations for their operations. CPT
lines, the company stresses, are of much higher
quality and reliability compared with Asian
machinery and offered at pricing levels that
allow small cable producers the possibility of
vertical integration.
© CPT
ALUMINIUM · 11/2013

Aktuelles / NeWs IN BRIef
fettfreier Gleitlack mit eingebautem
korrosionsschutz
Materialforscher am Leibniz-Institut für Neue
Materialien (INM) haben einen Gleitlack entwickelt,
der zwei Eigenschaften kombiniert: Er
hat ähnliche Schmiereigenschaften, wie man
sie von Fetten oder Ölen kennt, und schützt
zusätzlich vor Korrosion. Das neue Material
eignet sich als Beschichtung für Metalle wie
Stahl, Aluminium oder Magnesium.
Maschinenteile wie Zahnräder, Gewinde
oder Kurbeln verschleißen, wenn ihre metallischen
Oberflächen aufeinander reiben. Dagegen
helfen Schmierstoffe oder Funktionsöle.
Sie verbinden sich mit Schmutz, Abrieb und
Staub und verklumpen oder verharzen nach
einiger Zeit. Dann müssen Maschinenteile aufwändig
gereinigt und nachgefettet werden –
häufigere Wartungen, höherer Ressourcenverbrauch,
umweltbelastende Abfälle oder
zeitweise Maschinenausfälle sind die Folgen.
Die Forscher am INM entwickelten jetzt einen
Gleitlack, der fettfrei und zusätzlich vor Korrosion
schützt.
Das Besondere an dem Gleitlack ist seine
Zusammensetzung und Struktur. Carsten
Becker-Willinger, Leiter des Programmbereichs
Nanomere, erklärt: „Wir haben plättchenförmige
Festkörperschmierstoffe und
plättchenförmige Teilchen in ein Bindemittel
eingebettet. Beim Auftragen dieses Gemisches
auf eine Oberfläche entsteht ein wohlgeordnetes
Gefüge, in dem sich diese verschiedenen
Partikel dachziegelartig anordnen.“ So bilde
sich zwischen Gleitlack und Gegenkörper
ein Transferfilm aus, durch den Oberflächen
reibungsarm aufeinander gleiten. „Erst durch
das besondere Mischungsverhältnis hat unser
Komposit einen sehr niedrigen Reibungskoeffizienten.
Würden wir nur den Festkörperschmierstoff
verwenden, wäre der Reibungskoeffizient
deutlich höher“, so der Chemiker.
Die Dachziegelstruktur sorgt nicht nur für
reibungsarmes Gleiten, sondern wirkt wie
eine Barriere. Damit verhindert das Material
zusätzlich das Vordringen von Feuchtigkeit
oder Salzen auf Metalloberflächen. So schützt
es zusätzlich vor Korrosion. Im neutralen
Salzsprühtest zeigt das Komposit auf niedrig
legiertem Stahl eine Korrosionsbeständigkeit
von über 1.000 Stunden.
Der Gleitlack lässt sich mit den klassischen
nasschemischen Verfahren aufbringen, zum
Beispiel durch Sprühen oder Tauchen. Durch
einfaches thermisches Aushärten bildet sich
die Dachziegelstruktur ohne weiteres Zutun in
Selbstorganisation aus.
Alcoa surprises with strong Q3 performance
Aluminium giant Alcoa has recently reported
a sequential and year-over-year increase in
third quarter profit for 2013 driven by strong
operating performance and productivity gains,
despite lower metal prices. Net income was
USD24m. Excluding the impact of special
items, net income was USD120m. Results
were led by continued strength in Engineered
Products and Solutions and Global Rolled
Products, despite traditional third quarter
weakness. Global Primary Products overcame
falling metal prices and lower premiums to
deliver significant performance improvement
through productivity gains. The company
reported Q3 2013 revenues of USD5.8bn,
steady compared with the previous quarter
and the year ago period, despite a 3% sequential
and 7% y-o-y decline in the LME cash
price of aluminium.
“Our repositioning is on the right path,”
stressed Klaus Kleinfeld, Alcoa chairman and
chief executive. “We continued to build our
value-add businesses, capturing demand for
innovative material
solutions
across multiple
markets. Our
commodity
business delivered
better
performance
in a tougher
market environment,
and
we continued
to reshape the
portfolio to
lower the cost
base. Across
the board, productivity was exceptional –
achieving our full year target in the first nine
months.”
Alcoa reaffirms its 7% growth forecast
for global aluminium demand in 2013, with
an impressing 9-10% plus in the aerospace
market. The automotive market is expected to
grow by 1-4%, packaging by 1-2% and commercial
building and construction by 4-5%.
In the heavy truck market, Alcoa has raised
its 2013 growth expectation to 5-9% (previously
3-8%), on improvements in the European
market and a stronger Chinese market.
Investment projects well underway: Alcoa
made progress on its capital investments
to capture value-added growth opportunities,
and continued to take definitive actions in
Q3 2013 to improve its position on the alu-
Aluminium coil storage at Alcoa‘s Tennessee plant
minium cost curve.
The USD300m automotive expansion of
the Davenport plant in Iowa is set to be completed
by the end of 2013 with the commissioning
process currently underway. Construction
also began on the USD275m automotive
expansion at Alcoa’s rolling mill in Tennessee.
Both will support the growing demand for
aluminium sheet for automotive production.
Aluminium sheet per vehicle is expected
to grow 10-fold by 2025 in North America
alone.
The Ma’aden-Alcoa joint venture project
that will create one of the world’s lowestcost
integrated aluminium facilities is on time
and on budget. The smelter is 99% complete
and full operating capacity of 740,000 tonnes
a year is expected in 2014. This smelter will
contribute an estimated two percentage points
toward the company’s 2015 goal of lowering
its position on the world aluminium production
cost curve by 10 percentage points overall.
The joint
venture’s
380,000m tpy
integrated rolling
mill is 88%
complete. First
hot coil for the
rolling mill is
anticipated in
Q4 this year.
Construction
of the alumina
refinery
and bauxite
mine are also
on schedule.
First alumina out of the facility and bauxite
out of the mine are expected in 2014.
To further improve competitiveness, Alcoa
continues to review its global smelting
capacity and take action on higher-cost plants
and plants with long-term risk due to factors
such as energy costs or regulatory uncertainties.
In the first five months since announcing
the 460,000-tonne capacity review, Alcoa
has closed or curtailed 274,000 tonnes, equal
to 60% of the capacity under review. Most
recent actions include the permanent closure
of a potline representing 41,000 tonnes
at the Massena East plant in New York and
the temporary curtailment of 128,000 tonnes
of capacity in Brazil.
Alcoa now has 16%, or 651,000 tonnes, of
smelting capacity offline.
© Alcoa
ALUMINIUM · 11/2013

NeW s IN B RIef
senaat and Ducab in joint Abu Dhabi aluminium rod venture
Kizad Master Plan
Senaat, an Abu Dhabi state-owned industrial
holding company, and power cable maker Ducab
are linking up to open a Dh220 million
(USD60m) aluminium rod mill in Abu Dhabi,
providing a boost to the emirate’s strategy to
develop a downstream industrial heartland.
Based in the Khalifa Industrial Zone (Kizad),
the plant will produce aluminium alloy rods
and wires for use in cable-making and other
manufacturing as well as bare overhead conductors,
mainly for use in the utility industry.
“This new joint venture with Ducab is a
testament to our ability to successfully create,
optimise and champion industrial assets in
Abu Dhabi and the UAE, creating value and
further expanding the country’s industrial capabilities,”
said Suhail bin Athaeeth, the chief
executive of Senaat. It jointly owns Dubaibased
Ducab with Investment Corporation of
Dubai, a sovereign wealth fund owned by the
Dubai Government.
Known as Ducab Aluminium, the venture
will start plant construction in the first quarter
of next year, ready for opening in early 2016.
The facility aims to reach a capacity of 50,000
tonnes a year. The mill will be the latest project
within Kizad’s Hot Metal Road, a special
route for transporting liquid molten aluminium
straight away from the Emirates Aluminium
(Emal) smelter to processing industries
spanning extrusion to casting. The process cuts
the cost involved in re-melting the metal.
Officials see the linking up of metal producers
with manufacturers further down the
industrial value chain as vital to broadening
the depth of Abu Dhabi’s non-oil economy
and adding value to its exports. The mill will
not be the first aluminium rod manufacturer
in the region. Producers in Bahrain and Oman
both already make such products.
Ducab Aluminium will draw upon Ducab’s
sales network, at first targeting markets in the
GCC and Mena regions. European and Indian
subcontinent markets will be tapped later.
Overhead conductors will be sold to Ducab’s
existing customers of underground cables.
Rods will be used as material in Ducab’s Jebel
Ali facility in Dubai for making cables. Headquartered
in Jebel Ali, the company has been
making cables since 1979. It already has a
presence in Abu Dhabi through the operation
of a copper rod mill in Mussafah.
The venture is also the latest example of
Dubai and Abu Dhabi companies working together.
In June, a merger was announced between
Emal and Dubai Aluminium (Dubal),
to create a new larger aluminium producer,
Emirates Global Aluminium.
Sennat, along with Gulf Extrusions Co.
(LLC), is also parent company of Talex, the
Taweelah Aluminium Extrusion Company,
which is the first aluminium downstream
project to be established in Kizad. Talex is being
built on a 200,000 m 2 site adjacent to Emal,
and will be the first project on the Hot Metal
Road to receive liquid metal from the aluminium
smelter. The manufacturing capacity will
be 50,000 tonnes a year.
© Kizad
Novelis completes usD400m expansion of aluminium rolling mills in korea
Novelis has completed its USD400 million
investment programme in South Korea. The
expansion of its Yeongju and Ulsan plants
increases the company’s production capacity
in the region by more than 50% to around
1 million tpy of aluminium sheet. The expansion
is a key element in Novelis’s global growth
strategy. Phil Martens, president and chief executive
of Novelis, pointed out: “Asia is the
largest and fastest growing region in the world
for aluminium, and this expansion allows us
to maintain our leadership in this dynamic region
across key markets such as beverage cans,
consumer electronics and automobiles.”
Novelis began the expansion of its aluminium
rolling and recycling facilities in 2011 to
meet the rising demand for flat rolled aluminium
in high value-added products in the Asian
market. The expansion includes a hot and
cold rolling mill, pusher furnace, high-speed
slitter and annealing furnaces, in addition to
the previously commissioned fully-integrated
recycling centre at Yeongju. Shashi Maudgal,
senior vice-president and president, Novelis
Asia, commented: “We can now supply coils
to our new automotive sheet finishing plant in
Changzhou, China, which is expected to commence
production in mid-2014. Furthermore,
we can now pursue new business opportunities
in high value-added markets like consumer
electronics where a high-quality surface finish
is required.”
The demand for aluminium in the Asian
automotive market is expected to exceed the
25% compound annual growth rate projected
globally over the next five years, as more car
manufacturers move to build lighter, more
fuel-efficient vehicles. The company’s expansion
in South Korea will help it meet this rapidly
growing market.
Novelis opened a new aluminium recycling
and casting centre at its Yeongju facility in October
2012. This operation is the largest aluminium
beverage can recycling centre in Asia,
with the capacity to produce 265,000 tonnes
of sheet ingot. The Yeongju Centre is one of
a series of recycling and casting expansion
projects launched by Novelis over the past
two years to increase its recycling and casting
capacity to 2.1 million tpy globally by 2015.
Novelis has a regional headquarters office
in Seoul, operates four plants in South Korea,
Malaysia and Vietnam and will commission its
new Chinese facility in 2014. Currently, the
group employs around 1,800 people in the region,
including 200 new staff added as part of
this expansion.
ALUMINIUM · 11/2013

W IRtsCHAft
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
zuschränken. Daraufhin konnte der
3M-Preis deutlich zulegen. Auf dieser
Grundlage zeigten viele Finanzinvestoren
Kaufinteresse und einige technische
Ankäufe verstärkten diese Rally. Die
Aluminiumnotierung folgte dem allge-
Die Aluminium LME 3M-Notierung
handelte im Monat September in einer
Spanne zwischen $1.775/t und $1.865/t.
Am 18. September kündigte die US-Notenbank
Fed an, ihr Ankaufsprogramm
von Staatsanleihen zunächst nicht einmeinen
Trend der NE-Metalle im letzten
Monat, schnitt jedoch ob der Unsicherheit
bzgl. hoher Bestände und der in
diesem Zusammenhang anstehenden
LME-Entscheidung nur unterdurchschnittlich
ab.
Auf- bzw. Abschlag für 3-Monatstermin
Letzten 6 Durchschnittswerte LME
September 2013 35,54 Euro
August 2013 36,34 Euro
Juli 2013 33,88 Euro
Juni 2013 30,36 Euro
Mai 2013 24,80 Euro
April 2013 25,22 Euro
2005 2006 2007 2008 2009 2010 2011 2012 2013
0
50
–50
Aluminium High Grade, Kasse
Letzten 6 Durchschnittswerte LME 2.500
September 2013 1.318,33 Euro
August 2013 1.363,21 Euro
Juli 2013 1.351,17 Euro
Juni 2013 1.376,16 Euro
Mai 2013 1.410,51 Euro
April 2013 1.424,60 Euro
2005 2006 2007 2008 2009 2010 2011 2012 2013
2.000
1.500
1.000
Aluminium Lagerbestände
Letzten 6 Monatsendwerte LME
6.000
September 2013 5.381.000 t.
August 2013 5.400.350 t.
Juni 2013 5.435.600 t.
Mai 2013 5.202.000 t.
April 2013 5.157.625 t.
März 2013 5.237.400 t.
2005 2006 2007 2008 2009 2010 2011 2012
2013
5.000
4.000
3.000
2.000
1.000
0
Alle Angaben auf dieser Seite sind unverbindlich.
Quelle: TRIMET Aluminium SE – aktuelle LME-Werte unter www.trimet.de oder per TRIMET-App auf das iPhone.
10 ALUMINIUM · 11/2013

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)
+/-
in % *
Aug 34,9 -5,8 47,2 2,9 161,4 1,2 44,9 -11,8
Sep 33,6 -4,4 52,5 -4,3 164,5 8,1 44,6 -17,2
Okt 35,2 -2,5 53,3 -0,3 162,5 9,4 46,1 -7,4
Nov 34,2 -2,9 53,4 -6,4 152,9 0,1 42,5 -20,1
Dez 35,1 -2,1 43,4 -7,0 117,2 7,4 23,3 -22,8
Jan 13 35,4 0,3 52,2 -3,5 159,3 9,5 42,8 -7,6
Feb 33,8 4,4 52,6 -5,3 158,9 6,5 44,3 -7,2
Mär 39,9 17,0 54,4 -5,0 163,1 -1,7 45,5 -9,8
Apr 40,3 20,2 53,9 1,0 173,1 17,6 48,7 8,2
Mai 42,3 23,1 51,5 -5,1 163,2 1,5 45,3 -7,4
Juni 41,7 26,2 51,1 -6,3 162,9 1,2 48,4 -1,4
Juli 43,3 24,4 52,0 -7,1 164,4 -1,2 48,3 2,9
Aug 43,1 23,4 45,4 -3,8 159,8 -0,9 46,3 3,2
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
sekundäraluminium
Walzprodukte > 0,2 mm
Press- und Ziehprodukte
12 ALUMINIUM · 11/2013

W IRtsCHAft
trimet baut Automotive-Bereich aus
und erschließt neue Geschäftsfelder
Mit einem Umsatz von 1,2 Milliarden
Euro (Vorjahr: 1,3 Mrd. €) hat die Trimet
Aluminium SE das Geschäftsjahr
2012/2013 zur Jahresmitte abgeschlossen.
Mit einem Jahresüberschuss von 1,7
Millionen Euro kehrte das mittelständische
Unternehmen in die Gewinnzone
zurück. Trotz des leichten Umsatzrückgangs
verzeichnete der Werkstoffspezialist
eine gute Auftragslage, insbesondere
im Automotive-Bereich. Trimet produzierte
mit 1.924 Mitarbeitern an seinen
Standorten nahe der Kapazitätsgrenze
von 500.000 Tonnen Aluminium: rund
300.000 Tonnen Primärmetall und rund
200.000 Tonnen Recyclingmaterial (Primärschrotte
und Bearbeitungsspäne). Im
laufenden Geschäftsjahr 2013/14 soll das
Automotive-Geschäft weiter ausgebaut
werden. Die Übernahme zweier Produktionswerke
für Aluminiumdraht in Frankreich
steht laut dem Vorstandsvorsitzenden
Martin Iffert kurz bevor und wird
damit neue Geschäftsfelder erschließen.
Mit einer Eigenkapitalquote von 40,2
Prozent verfügt das nicht börsennotierte
Unternehmen über eine solide Handlungsbasis.
➝
trimet extends its automotive sector
and develops new business fields
With a turnover of 1.2 billion euros (previous
year: €1.3 bn) Trimet Aluminium
SE concluded its business year 2012/13 in
mid-year. With a net income of 1.7 million
euros the company has returned to
profitability. Despite the slight turnover
decline the company reported a good
order position, particularly in the automotive
sector. Trimet, which employs
1,924 people at its various locations,
produced amounts close to its capacity
limit of 500,000 tonnes of aluminium:
around 300,000 tonnes of primary metal
and 200,000 tonnes of recycled material
(primary scrap and machining swarf). In
the current financial year 2013/14 the automotive
business is to be extended further.
According to chief executive Martin
Iffert, the takeover of two production
plants for aluminium wire rod in France is
imminent and this will open up new business
fields. With an equity ratio of 40.2%
the company, which is not quoted on the
Stock Exchange, has a solid trading basis.
The slight turnover decline compared with
last year can be attributed to the recently low
international prices of aluminium. In addition,
owing to the renewal of electrolysis pots the
full production capacity was not available.
Over the past year Trimet noted unabated
demand from the transport, building and
packaging industries, for special aluminium
alloys and semis. “Our order-books are full
and there is no sign of an end to that trend,”
said Mr Iffert. The worldwide demand for aluminium
is expected to double between 2010
and 2020. To be able to meet the persistently
high demand for casting alloys, Trimet has
almost doubled its capacities in that sector
with a new ingot casting plant. In all, the company
invested nearly 40 million euros during
the last financial year for the extension and
modernisation of its production facilities.
An important growth market is vehicle
construction. Besides special alloys, for the
automobile industry Trimet produces engine
blocks, transmission and clutch housings,
mechatronic components for transmissions,
© Trimet
Trimet-Elektrolyse …
Trimet potroom …
14 ALUMINIUM · 11/2013

eCoNoMy
structural and chassis components and pressure-diecast housings.
Despite rather lower automobile passenger-car sales the rising demand
for structural components made of aluminium is a force for
growth. “Our own metal basis, our know-how about materials and
our orientation toward complex castings with a greater processing
depth has proved a lasting strategy, for our customers as well,” said
Mr Iffert. At its location in Harzgerode Trimet has considerably extended
Germany’s most up-to-date gravity-diecasting foundry for
chassis components. The production of a transmission and clutch
housing for a noted automobile manufacturer, alone, will keep four
large pressure diecasting machines busy until beyond 2020.
W E C O N V E Y Q U A L I T Y
Defined Cooling of
Hot Bath Material
takeover of french plants imminent
With the takeover of two production plants in Saint-Jean-de-Maurienne
and Castelsarrasin for high-grade wire rod and the electrolysis
material required for them, Trimet is enlarging its portfolio to include
a product with great market potential. In this connection Mr
Iffert points to the necessary extension of the power grid in Germany,
for which aluminium wire will be needed. Moreover, the automobile
industry too needs aluminium wire, for example for connection
elements. In that context aluminium is competing as a material
against copper. Taken together, the two plants in France employ
about 500 people.
For the Primary Aluminium
Smelting Process
… und Gießerei in Essen
… and casthouse in Essen
Until now the market for wire rod was served by Trimet’s trading
activities. However, customers increasingly call for tailor-made solutions.
“So the two facilities fit in admirably with Trimet’s strategic
orientation. That is true of both the products and the high technological
level of their aluminium electrolysis.” The plants were originally
built by the French group Pechiney, at that time a technology
leader in the production of aluminium. Today they belong to Rio
Tinto Alcan (RTA), which for strategic reasons wants to withdraw
from that area of business. In 2012 RTA produced around 93,000
tonnes of smelted aluminium in Saint-Jean-de-Maurienne and 8,000
tonnes of wire rod in Castelsarrasin. However, the total capacity is
larger: Trimet mentions a figure of 150,000 tonnes.
Mr Iffert did not say anything specific about the purchase price,
other than to say that: “The takeover conditions allow us to plan our
investments dependably and in the long term.” In July Trimet made
a binding offer for the takeover of the RTA plants, and the negotiations
seem far advanced: “We expect to be taking over both plants
ALUMINIUM · 11/2013
AUMUND Foerdertechnik GmbH

W IRtsCHAft
in the near future,” he said. Trimet has also
received broad support for the takeover from
the works councils of both plants. Antitrust approval
for the takeover is expected to come
through this year. And long-term power supply
contracts have already been negotiated
with the French power utility EDF.
Partial compensation for
Co 2 costs since January 2013
Das Geschäft für Automotive-Produkte läuft gut…
Business for automotive products is well underway …
Der leichte Umsatzrückgang im Vergleich zum
Vorjahr ist auf die zuletzt niedrigen internationalen
Aluminiumpreise zurückzuführen.
Zudem stand infolge der Erneuerung von
Elektrolyseöfen nicht die volle Produktionskapazität
zur Verfügung. Trimet verzeichnete
im abgelaufenen Geschäftsjahr eine ungeminderte
Nachfrage der Transport-, Bau- und
Verpackungsindustrie nach spezialisierten
Aluminiumlegierungen und -halbzeugen. „Unsere
Auftragsbücher sind gefüllt, und ein Ende
des Trends ist nicht abzusehen“, sagte Iffert.
Der weltweite Bedarf an Aluminium werde
sich im Zeitraum 2010 bis 2020 verdoppeln.
Um den anhaltend großen Bedarf an Hüttengusslegierungen
bedienen zu können, hat
Trimet mit einer neuen Masselgießanlage ihre
Kapazitäten in diesem Bereich nahezu verdoppelt.
Insgesamt investierte das Unternehmen
im zurückliegenden Geschäftsjahr fast
40 Mio. Euro in den Ausbau und die Modernisierung
seiner Produktionsanlagen.
Ein wichtiger Wachstumsmarkt ist der Fahrzeugbau.
Neben spezialisierten Legierungen
fertigt Trimet für die Automobilindustrie Motorblöcke,
Getriebe- und Kupplungsgehäuse,
Mechatronikteile für Getriebe, Struktur- und
Fahrwerksteile sowie Druckgussgehäuse. Als
Wachstumstreiber erweist sich trotz eines
abgeschwächten Pkw-Absatzes der steigende
Bedarf an Strukturteilen aus Aluminium.
„Unsere eigene Metallbasis, unser Werkstoff-
Knowhow und die Ausrichtung auf komplexe
Gussteile mit großer Bearbeitungstiefe erweist
sich auch für unsere Kunden als nachhaltige
Strategie“, so Iffert. An ihrem Standort Harzgerode
hat Trimet Deutschlands modernste
Kokillengießerei für Fahrwerksteile erheblich
erweitert. Allein die Produktion eines Getriebe-
und Kupplungsgehäuses für einen namhaften
Automobilhersteller wird vier große
Druckgussmaschinen bis über das Jahr 2020
hinaus auslasten.
Übernahme französischer
Werke steht kurz bevor
Mit der geplanten Übernahme zweier Produktionswerke
in Saint-Jean-de-Maurienne
und Castelsarrasin für hochwertigen Gießwalzdraht
und dem dafür benötigten Elektro-
The company’s development will benefit from
political moves being made to break down barriers
to competition. By virtue of the implementation
of the European directive on CO 2
emissions, since January 2013 Trimet has
received partial compensation for CO 2 costs
previously included in the price of electrical
power. In the context of the Abschaltlastverordnung
(Interruptible Loads Regulation)
the company also receives a reimbursement
for contributing to the stabilisation of
the power grid. The Trimet aluminium smelter
in Hamburg is the first industrial operation
in the world outside the energy supply sector
which participates in the primary control
reserve to ensure network stability. In this
way Trimet makes an important contribution
toward relieving the load on transmission
networks for power supply.
“The emissions directive and the Abschaltlastverordnung
are moving in the right direction,”
Mr Iffert said. “The now urgently anticipated
policy decisions on the reconstruction
of the energy supply system must also be led
by the aim of maintaining the competitiveness
of the domestic raw materials industry.” n
… und soll weiter ausgebaut werden
… and will be further developed
1 ALUMINIUM · 11/2013

eCoNoMy
lysematerial erweitert Trimet ihr Portfolio um
ein Produkt mit großem Marktpotenzial. Iffert
verweist dazu auf den erforderlichen Ausbau
der Stromnetze in Deutschland, für den
Aluminiumdraht benötigt wird. Des Weiteren
benötigt auch die Automobilindustrie Aludraht,
bspw. für Verbindungselemente. Hier
steht Aluminium im Substitutionswettbewerb
mit Kupfer. Die beiden französischer Werke
beschäftigen zusammen gut 500 Mitarbeiter.
Bislang wurde der Markt für Gießwalzdraht
über die Handelsaktivitäten der Trimet
bedient, doch verlangten die Kunden zunehmend
maßgeschneiderte Lösungen. „Deshalb
fügen sich die beiden Standorte hervorragend
in die strategische Ausrichtung der Trimet ein.
Das gilt für die Produkte ebenso
wie für das hohe technologische
Niveau der Aluminiumelektrolyse.“
Die Werke wurden ursprünglich
vom französischen
Pechiney-Konzern errichtet,
seinerzeit ein Technologieführer
in der Aluminiumproduktion.
Die Werke gehören heute
der Rio Tinto Alcan (RTA), die
sich aus strategischen Gründen
aus diesen Geschäftsfeldern
zurückziehen will. RTA produzierte
2012 rund 93.000
Tonnen Hüttenaluminium in
Saint-Jean-de-Maurienne und
8.000 Tonnen Gießwalzdraht
Castelsarrasin. Die Gesamtkapazität
liegt jedoch höher:
Trimet spricht von 150.000
Tonnen.
Zum geplanten Kaufpreis
machte Iffert keine konkreten
Angaben, nur soviel: „Die
Konditionen der Übernahme
erlauben uns eine verlässliche
und langfristige Investitionsplanung.“
Im Juli hatte Trimet ein
verbindliches Angebot für die
Übernahme der RTA-Standorte
vorgelegt. Die Verhandlungen
scheinen weit gediehen:
„Wir gehen davon aus, dass
wir die beiden Werke in Kürze
übernehmen werden“, sagte
er. Breite Unterstützung für die
Übernahme habe Trimet auch
durch die Betriebsräte der beiden
Werke erhalten. Die kartellrechtliche
Genehmigung
der Übernahme wird noch für
dieses Jahr erwartet. Auch mit
dem französischen Stromver-
WWW.BUSSCORP.COM
sorger EDF sind bereits langfristige Stromverträge
ausgehandelt.
teilkompensation für
Co 2 -kosten seit Januar 2013
Der Unternehmensentwicklung kommt auch
zugute, dass seitens der Politik Wettbewerbshemmnisse
abgebaut wurden. Mit der Umsetzung
der europäischen Kohlendioxid-Emissionsrichtlinie
erhält Trimet seit Januar 2013
eine Teilkompensation der bislang im Strompreis
enthaltenen CO 2 -Kosten. Im Rahmen
der Abschaltlastverordnung erhält das Unternehmen
zudem eine Vergütung dafür, dass es
zur Stabilisierung des Stromnetzes beiträgt.
The leading Mixing Technology
for Anode Pastes
Die Aluminiumhütte der Trimet in Hamburg
ist der weltweit erste Industriebetrieb außerhalb
der Energieversorgungsbranche, der an
der Primärregelreserve zur Sicherung der
Netzstabilität teilnimmt. Damit leistet Trimet
einen wichtigen Beitrag zur Entlastung der
Übertragungsnetze für die Stromversorgung.
„Die Emissionsrichtlinie und die Abschaltlastverordnung
weisen in die richtige Richtung“,
so Iffert. „Die jetzt dringend anstehenden
politischen Entscheidungen zum Umbau der
Energieversorgung müssen ebenfalls von dem
Ziel geleitet sein, die Wettbewerbsfähigkeit
der heimischen Grundstoffindustrie zu erhalten.“
n
For over 50 years BUSS KE and CP series Kneaders have been
the benchmark for reliable, cost-effective compounding of
anode pastes. Now we go one step further.
ALUMINIUM · 11/2013

economy
current picture of the primary aluminium industry
This article is part of a comprehensive
paper by Dr Carmine Nappi – ‘A Review
of the Global Aluminium Industry: 1972-
2012’ – published at www.worldaluminium.org.
Reprinted by courtesy
of the International Aluminium Institute
(IAI).
The geographic distribution of bauxite, alumina
and aluminium production has shifted
significantly since 1972. Starting with bauxite,
while Australia increased its share of global
output from 20% to 32% over the last
40 years, Jamaica, Suriname and Russia are
no longer on the list of the major producers,
having been replaced by Brazil (15%), China
(14%) and Indonesia (11%). The combined
market share of the four largest producers is
now over 70%.
A complete relocation of producing centres
has also been taking place in the global
alumina industry. The production shares of
Japan, Russia, Jamaica and Suriname have
drastically shrunk since 1972 – and today four
countries (China, 35%; Australia, 23%; Brazil,
11%; India, 4%) have a combined share
of 73% of global alumina output. While the
BRIC countries now account for almost 40%
of global bauxite output, this share jumps to
53% for alumina. In the latter case, production
has definitely shifted towards countries
with access to an abundant and inexpensive
source of bauxite. In addition to being the
most important cost element, the bauxite cost
is the most important source of variation of
alumina production cost. China has become
the largest alumina producer, but continues
to import a large share of its bauxite needs,
mainly from Indonesia.
If bauxite cost remains the most significant
driver of the current location of alumina production,
shifts in the geographic location of
aluminium production is determined to a large
extent by variations in energy prices. Even if
capital, alumina and energy costs account for
about equal shares of total aluminium production
costs, energy costs vary much more
between countries than the two other cost
elements; consequently, energy costs remain
the most important determinant of international
differences in aluminium production
costs (about 70% of the variability in aluminium’s
total cost is linked to energy cost).
Unsurprisingly, US share of global primary
output has moved down from 32% in 1972 to
only 4% in 2010. The same applies to Japan
(its share dropping from 9% to nil during the
Fig. 1: Market shares
and degree of concentration
in global bauxite,
alumina and primary
aluminium capacities
(2010)
same period) and most European producer
countries of the early 1970s, with the exception
of Iceland and Norway.
Primary output has been moving to China
(with around 40% market share) not only
because of its natural sources of comparative
advantage (energy is abundant and relatively
cheap in its western and north-western
regions) but also because of policy-induced
sources of competitiveness related to provincial
subsidies, exchange rates and trade policies.
Other major producers include energyrich
regions such as Russia (9% in 2010),
Canada (7%), the Middle-East (6%), Australia
(5%), Brazil and India with 4% each.
The Middle-East region share is continuing to
grow with the commissioning of the Emal and
Qatalum smelters in 2011 and Ma’aden smelter
in 2013. Despite being endowed with vast
energy resources, Russian output has been
moving up during the last 20 years at a slower
Source: CRU Bauxite &
Alumina Market Outlook,
July 2011, and Aluminium
Quarterly Industry & Market
Outlook, July 2011
pace than global production, bringing down its
market share.
What are the other new characteristics of
the global aluminium industry?
Lower degree of concentration and
integration, and more ‘strategic groups’
The arrival of new private or state-owned enterprises
has also completely modified the degree
of competition within the industry. Starting
with bauxite, not only the share of the
six major producers has dropped to about
50% in 2010 (the HH index also lost ground
to reach 0.058 during the same period), but
even the players have changed: Alcoa (10.6%)
is still present through a 60% ownership of
Awac and Alcan was acquired by Rio Tinto
providing Rio Tinto Alcan (RTA) with a market
share of 13.1%; the others have been
replaced by Alumina Ltd. (7% through its
18 ALUMINIUM · 11/2013

economy
40% ownership of Awac), Hydro (a proforma
share of 6.1% in 2010 since Hydro
acquired Vale’s aluminium business on 28
February 2011), BHP Billiton (6%), UC
Rusal (5.5%) and Chinalco/Chalco (4.6%).
The story is similar in the global alumina
Intralogistik-Lösungen
neu im Internet unter
www.herrmannhieber.de
market. The share of the six most important
producers (CR 6) has come down from almost
80% to slightly more than 53% over the last
four decades. If the degree of concentration
is measured using the HH index, the drop is
even more important from 0.129 to 0.048.
Once again, while Alcoa (10.4%) and RTA
(9%) are still present, the other players are
newcomers: Chinalco / Chalco (11.9%), UC
Rusal (9.8%), Alumina Ltd (6.5%), Hydro
(6%) and Chiping Xinfa (5.8%). Fig. 1 highlights
the significant presence of Chinese
alumina producers – the cumulative share of
Chinalco / Chalco, Chiping Xinfa, East Hope
Group and Weiqiao was around 24% in 2010.
As expected, the arrival of new players has
also reduced the degree of concentration in
the global primary aluminium industry. The
share of the original Six Majors back in 1972
has dropped from 73% to 38% four decades
later. Given the disappearance of very large
players, the HH index suggests a much more
drastic drop from 0.103 to 0.027. No single
company in 2010 had a degree of ownership
of the global primary capacity exceeding 9%,
while three Chinese producers (Chinalco /
Chalco, 6%; China Power Investment, 2.3%;
and Xinfa Group, 2.1%) had a combined share
of 10.4%.
However, the most distinctive feature of
the current global aluminium industry is the
fact that many producers are not fully integrated
with upstream and downstream assets.
For example, RTA and BHP represent large
conglomerates with no downstream facilities
but with large upstream interests. On the other
hand, Alcoa and Hydro (since the 2010 acquisition
of Vale’s aluminium assets) are fully
integrated, while UC Rusal, Chinalco / Chalco
and some Chinese producers are stronger upstream
than downstream. Finally, some large
producers such as Alba and Dubal are focused
on the smelting stage of the production value
chain.
The various types of producers reflect not
only a lower degree of integration over time
but also the presence of many ‘strategic
groups’, defined as clusters of firms following
the same strategy, making the same type of
choices with respect to some key variables
such as resource commitments, and thus having
the same interests. An increase in the
price of aluminium is certainly positive for
‘upstream-only integrated producers’, while
being detrimental to those with downstream
operations fighting for a higher market share
relative to substitutes. The degree of competition
within an industry is positively correlated
with the number of strategic groups, suggesting
that competition within the aluminium industry
may be even larger than what is indicated
by the current degrees of concentration.
Shifts in consumption patterns
by region and by end-use market:
china and transportation dominate
Global primary aluminium consumption has
been increasing at a compounded annual
growth rate (CAGR) of about 5% over the last
decade, despite two recessions and continuous
market threats of substitutes. During this
period, demand growth rate has been much
faster in countries such as China (CAGR of
almost 17%) and India (10.4%) than in the
rest of the world (0.8%), reflecting the growth
and growing importance of the BRIC countries.
This is better illustrated by Fig. 2 which
presents use of primary aluminium by region
in 2010.
In 1972, more than 60% of global consumption
of primary aluminium was taking
Fig. 2: Primary aluminium consumption (2010)
Source: WBMS, various years and Brook Hunt Long Term Outlook, July 2011
place in six industrialised countries, with the
United States leading the pack at 36%, followed
by Japan (10%), Germany, France, Italy
and the United Kingdom.
In 2010, the combined share of these same
industrialised countries was barely exceeding
25%. The same is true for Russia: its market
share dropped from 12% in 1972 (for USSR)
to less than 2% in 2010.
The leading role in global consumption is
now played by China whose market share has
swelled from 2% in 1972 to 40% today. As for
India and Brazil, they have more than doubled
their market share. Thus, almost half of global
primary consumption is today accounted by
BRIC economies.
What about the total aluminium consumption
by end-use market? Transportation has
become the most significant end-use market,
accounting for almost 43% of the metal used
in Japan and 35% of North American and
West European aluminium shipments. This
contrasts with the situation 40 years ago when
this end-use market was responsible for about
20% of total consumption in the United States,
Japan or Germany.
According to Ducker Worldwide, a wellknown
research firm in this field, automakers
are accelerating their shift to aluminium
away from other materials for new car and
light truck construction in order to safely and
cost-effectively lower the weight of their vehicles.
Ducker’s survey of North American auto
producers indicates that since lighter vehicles
get better fuel economy with fewer emissions,
aluminium is already the leading material in
20 ALUMINIUM · 11/2013

SYSTEMS AND EQUIPMENT FOR THE METAL INDUSTRY
Leading solutions for automatic
anodes slotting machines
Advanced anodes slotting machines to cut deep, straight, inclined and interrupted slots.
T.T. TOMORROW TECHNOLOGY S.p.A.
Via Dell’Artigianato, 18 - I - 35020 DUE CARRARE (PD) ITALY Tel. +39 049 9128800 - Fax +39 049 9128888
www.tomorrowtechnology.it

economy
the engine and wheel markets and is gaining
market share in hoods, trunks (boots) and
doors. Aluminium usage has increased every
year for nearly 40 years to reach 148 kg in
2009 and should hover around 156 kg in 2012.
Stricter fuel economy regulations should accelerate
the use of aluminium in bumpers,
heat shields, brake calipers, ABS and driveline
components, cylinder heads or bed plates.
However, the market challenge from alternatives
remains present: the steel industry
continues to invest millions of dollars to demonstrate
that high strength steels can be engineered
to provide the same weight savings as
aluminium; composites (like carbon fibre) also
represent a serious competitor in the automotive
and aerospace sectors. Although composites
have a cost and repair disadvantages, their
price is coming down while offering improved
corrosion properties and good aesthetics.
As for the other end-use markets, a number
of circumstances favour aluminium:
• the copper to aluminium substitution (as
the price differential reached record
highs) in overhead cables, heat sinks for
electronics, utility bus bars, battery cables,
wire harnesses and aluminium wiring in
air conditioners and white goods
• the wider use of aluminium in consumer
electronics for backing plates for flat
screen TVs (a lightweight alternative to
steel), tablet computers, mobile phones,
laptops or as a laminated film used in
exterior packaging for batteries
• the use of aluminium in green applications
such as solar panelling (used in the frame)
and wind farms (in submarine cables for
off-shore wind farm projects).
However, substitution can work both ways –
and aluminium remains under challenge in the
buildings sector where plastics have become
increasingly popular, in the aerospace sector
with inroads by composites and in the US
packaging industry where aluminium has lost
Planung, Konstruktion und Ausführung
von Industrieofenanlagen
Konstantinstraße 1a
41238 Mönchengladbach
Telefon +49(0)2166/987990
Telefax +49(0)2166/987996
E-mail info@inotherm-gmbh.de
Internet www.inotherm-gmbh.de
market share in the individual drinks market
to plastic bottles.
Investor demand and market
fundamentals as price drivers
As for most commodities, the global aluminium
industry is characterised by a strong relationship
between the real price of the metal
and the gap between demand and supply of
the metal as captured by the variations in total
stocks (including both visible and unreported
inventories) expressed in weeks of shipments.
Prices tend to explode for very low levels of
inventories, while being quite stable despite
high level of inventories as prices cannot drop
below their average operating costs for a long
period of time. As mentioned earlier exchange
rates also play a role given that aluminium
prices are generally expressed in US dollars –
thus a weaker dollar drives up the US-dollar
price of aluminium.
However, since the middle of the past decade,
another aluminium price determinant has
been identified with the rise in popularity of
commodities as an asset class, with investors
using a variety of instruments and strategies to
gain exposure to commodity prices. The most
important investment vehicles used include:
• various Commodity Index Funds (CIFs),
where investments are made through the
purchase of commodity futures, which are
then rolled forward by being sold at or prior
to maturity and replaced with a new futures
purchase with a more distant maturity date as
long as they provide positive returns from rising
spot commodity prices
• Commodity Trading
Advisors (CTAs)
or momentum investors
where decisions to
buy or sell are based
on trends or technical
factors (mainly past
patterns of price behaviour)
• hedge funds where
investment decisions
are based on their
view of the economy
outlook or of the metals’
fundamentals
• proprietary trading
desks of major investment
banks or trading
firms that invest in
commodities on their
own account (note that
some of these major
banks and commodity
traders have their own warehouses and provide
incentives to metal holders to guarantee
that enough metal would sit in their warehouse
at full rent to cover the cost of the incentives
paid; these stocks are referred to as
‘stealth or unreported’ stocks since their importance
may only be estimated).
What is the impact of this investor demand
on spot aluminium prices?
The answer is not straightforward, even if
the rise in popularity of commodities’ investment
coincided with a surge in many commodity
prices. In general, spot prices (for immediate
delivery) are lower than future prices (in
the case of aluminium, official contracts exist
for 3-, 15, 27-, 63- and 123-months), and
the difference or ‘contango’ between the two
prices is high enough to at least cover finance
and warehousing costs.
The presence of such contango induces investors
to buy spot and sell futures, raising
the spot and reducing the futures prices until
the gain from the contango covers no more
than the costs mentioned above. Obviously,
near-zero interest rates and subsidised warehousing
costs increase the contango and thus
the expected return from such deals.
The same applies if the futures price moves
up because of higher investor demand: the
contango becomes wider, inducing more investors
to buy spot and sell forward, which
raises the spot price. In all other market circumstances
(insufficiently high contango or
spot prices higher than the futures price), the
mechanism linking spot and the futures price
is less clear as other variables such as expec-
Source: Derived from World Bureau of Metal Statistics (WBMS), various years
Fig. 3
22 ALUMINIUM · 11/2013

economy
tations about the futures price or the costbenefit
ratio of holding inventories must also
be taken into account.
Nevertheless, even if investor demand may
in some cases influence spot prices, this new
driver has made the traditional relationship
between supply, demand, stocks and prices
more murky not only because this influence
is not straightforward but also because of the
increased presence of unreported stocks. The
latter are currently estimated in the 3.0-4.5
million tonne range, which makes price forecasting
and apparent consumption calculations
more challenging.
outlook
The primary aluminium industry of today has
little resemblance to what it was 40 years ago.
BRIC economies now account for more than
40% of bauxite production, while alumina
output has shifted towards bauxite-rich countries
and away from industrialised economies.
Reacting to the continuous increase in energy
prices and in some cases to government industrial
policies, primary production has moved
from regions such as the United States, Japan
and most West European countries towards
China, Russia, Canada, Brazil, Australia, the
Middle-East, and now India and some parts of
South East Asia. The degree of competition has
surged, driven not only by lower concentration
and integration, but also by the presence of
different strategic groups with different economic
interests.
Significant structural changes have also
taken place on the demand side of the industry
equation where the 60% combined share of
global consumption held by six industrialised
countries in 1972 has shrank to 25%, replaced
by China (40% in 2010), India and Brazil.
As for end-use markets, transportation now
dominates, accounting for 35-40% of Japanese,
North American and West European
total shipments.
Aluminium spot prices are also more volatile
than 40 years ago: during the 1973-2011
period, the degree of volatility (standard deviation
over average prices) reached 0.335,
more than doubling the corresponding value
for the 1946-1972 period. Investor demand
has ‘financialised’ base metals markets. This
new driver may explain some of the increase
in metal prices when futures prices exceed
spot prices by a margin high enough to more
than offset financial and warehousing costs.
Other variables need to be taken into account
under alternative market hypotheses.
Looking forward, even if primary aluminium
consumption has been growing at a pace
of about 3% per year (see Fig. 3) over the
last 40 years, a higher CAGR of around 4.0%
can be expected over the next two decades as
urbanisation, industrialisation and economic
development in BRIC and other emerging
countries continue to positively impact the
use of aluminium.
Even if the consumption per capita of mature
economies such as Germany, South Korea,
Japan and the United States has stabilised
at around 20 kg in 2010 and may come down
slightly during the years ahead, this is not the
case for countries such as India (only 2 kg
per head), Brazil and Thailand (about 5 kg),
Turkey (8 kg) or Malaysia and China (slightly
above 10 kg per capita). If these countries follow
more or less the same pattern of growth
as the current mature economies, primary
aluminium consumption should double in the
next 20 years. Drivers such as stricter environmental
policies, energy efficiency, downsizing,
globalisation or the continuous development
of new applications may drive up the
use of aluminium at a faster rate than expected.
On the downside, the negative substitution
in favour of plastics or new materials, policies
favouring growth instead of sustainable
development or the challenge of developing
new applications in an industry as fragmented
as aluminium may result in less demand than
forecasted.
This growth projection implies the ‘equivalent’
of about 40-50 new smelters (with a capacity
of 500,000 tpy each) will be needed to
satisfy 2030 forecasted demand. The required
additional capacity will in fact be even higher
as some smelters will be dismantled or idled
during the same period. These expansions
(brownfield) and/or new investments (greenfield)
will raise new challenges in terms of
commissioning additional capacity of bauxite,
alumina and carbon products, and developing
new sources of
energy. Given that
electricity will remain
the most important
driver of
competitiveness,
the new smelters
will be found
in the Middle
East region, Russia,
the western
and north-western
provinces of
China, Malaysia,
Africa (including
Algeria, Angola
and the Congo),
India and other
regions where stranded energy can be available.
Policy-induced sources of competitiveness
(subsidies, legislation, undervalued exchange
rates) will remain present, influencing
not only the level of total supply but also
its distribution among the regions mentioned
above.
The future of the global aluminium industry
will be influenced by its ability to minimise
environmental impacts and to be considered
as a solution to some of the problems generated
by CO 2 emissions. For example, according
to a recent study by The Aluminum Association
(Sept. 2011), North American 2009
‘light-weighting’ of vehicles with aluminium
offset 90% of the energy consumption and
96% of cumulative greenhouse gas emissions
associated with primary aluminium production.
Even more, 75% of all the aluminium
ever manufactured – dating back 125 years
and over multiple generations – is still in use
today as the metal is recycled after each use
phase, further compounding the metal’s sustainability
dividends.
Just like the rise in energy prices in the
mid-1970s, legislation on CO 2 emissions may
impact both sides of the market simultaneously.
Supply growth may to some extent be
hindered by higher production costs related
to emissions and higher raw material and
power prices. However, CO 2 caps may also
favour the use of aluminium by encouraging
energy efficiency and light-weighting, with
potential beneficiaries in the transportation,
power distribution and transmission, air conditioning
and refrigeration, renewable energies,
green buildings and other end-use sectors.
Aluminium product characteristics such as
lightweight, strength, moderate melting point,
ductility, conductivity and corrosion resistance
will continue to be in demand well into
the future.
■
ALUMINIUM · 11/2013 23

economy
In the limelight – the Arabal conference 2013
The rise of the aluminium sector in the
Middle East is one of the remarkable
trends in this industry in recent years.
Although production in the region only
began in 1971, by 2020 smelters from
the Gulf are expected to contribute nine
percent of the world’s primary aluminium
production. Recognition of the increasingly
important role that the region plays
is just one of the reasons why leading representatives
from the industry will participate
in the Arabal 2013 Conference.
For the first time in its history this conference
will take place in Abu Dhabi, from 5 to 7 November,
with Emirates Aluminium (Emal),
UAE, as the host. The Middle East’s premier
trade event for the global aluminium industry
will both support the region’s position as a
leader in primary aluminium production and
showcase the advantages of doing business in
the Gulf Cooperation Council (GCC).
Arabal began in 1983 as a forum for the
region’s producers to discuss matters of mutual
interest. Over the past 30 years it has not
only helped to strengthen ties within the GCC,
but, reflecting development in the Gulf, has
grown beyond its regional origins, attracting
international prominence.
The growth of the aluminium sector in the
GCC can be traced back to the early 1970s.
In order to provide economic diversity beyond
oil and gas, governments in the region
identified aluminium as the metal of the future
and began investing in the infrastructure
needed to create a reliable source of quality
primary aluminium. The first GCC smelter
started production in Bahrain in 1971 and
was followed by the establishment of Dubai
Aluminium (Dubal) in the UAE, which began
operations in 1979. In 2007 the UAE announced
details of a second smelter for the
country and Emal was created in Abu Dhabi.
Oman’s Sohar plant started in 2008 followed
by Qatar’s Qatalum the following year. The
GCC currently has five smelters producing
primary aluminium and another smelter in
Saudi Arabia, the Ma’aden Alcoa joint venture,
near completion.
These investments were based upon the region’s
numerous strategic advantages, including
its proximity to major aluminium markets
in Europe, USA and the Far East. GCC smelters
export around 80 percent of their total
aluminium production, which highlights the
importance of the GCC’s role in the global
market.
Strategic advantages of the Gcc region
Port of the Khalifa Industrial Zone
One of the strategic advantages is access to
reliable and low-cost energy. In recent years
energy costs for many producers around the
world have increased, which makes the GCC
an all the more attractive location. However,
low energy costs are not the only reason why
smelters in the Gulf are on the upswing. As
there are recent investments in the region
for expanding or building new smelters, the
region is adopting the latest, highly efficient
technologies, which provides another business
advantage over competitors with older infrastructure.
Current primary aluminium production by
GCC smelters is four million tonnes a year,
which constitutes around 7.8 percent of total
world production. With additional facilities
set to come on stream over the next few years,
production capacity in the region is set to
rise to almost five million tonnes by 2015.
And this trend is set to continue with forecasters
estimating the GCC will be responsible
for nine percent of the world’s aluminium
production by 2020. Therefore, the region
is in ‘pole position’ to take advantage of
the forecasted six percent year-on-year rise in
global demand for aluminium over the next
decade.
However, GGC smelters are not only
aligned to overseas sales. A major factor in
the drive for economic diversification is developing
the local downstream industry. The
Gulf has access to huge regional and international
markets: situated between Asia and
Europe, advanced transportation links provide
ready access to around two billion consumers
across four time zones.
Projects, such as Abu Dhabi’s Kizad (Khalifa
Industrial Zone), support the diversification
of the local industrial base by establishing
hubs for manufacturing, logistics and trade
for both local and international companies to
take advantage of. Value is added at every
stage of the supply chain through efficiencies
of scale, proximity and market access.
Kizad is one of the world’s largest industrial
zones and has made aluminium a focus
for development. Emal is one of the zone’s anchor
clients and the proximity of Khalifa Port
allows easy and quick movement of goods and
raw materials. Kizad has also built the socalled
Hot Metal Road allowing delivery of
products directly from Emal to local companies.
The downstream targets for Kizad are
rolling and extrusion products as well as castings
and forgings for industries such as construction,
transport, packaging and engineering.
The latest project is the Senaat / Ducab
joint venture for aluminium rod. (For further
details see News in brief section in this issue).
By adding to the international profile of
GCC countries, providing sustainable income,
creating jobs and expanding the local economic
base, aluminium is proving to be a
major return on investment. This growing importance
will be reflected at the Arabal 2013
Conference. Already recognised as a strong
networking platform for the industry, it will
attract global aluminium leaders with an
agenda which will not only focus on developments
in the region, but also provide insights
and perspectives from around the world. ■
© Kizad
24 ALUMINIUM · 11/2013

...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

ALUMINIUM RoLLINg INDUSTRY
Rusal – largest producer of aluminium foil in Russia
UC Rusal, a leading global aluminium
producer, is also Russia’s largest producer
of aluminium foil and packaging
materials made from aluminium foil. The
Packaging division comprises four foil
mills: Sayanal, Armenal, Ural Foil and
another plant under the brand ‘Sayanskaya
Foil’, where household foil is rolled
and packed. Rusal’s Packaging division
mostly produces household and technical
foil, converter foil and foil­based packing
materials. At present, the Packaging division
makes 81,000 tonnes of aluminium
foil a year. By 2016 Rusal plans to invest
USD17 million to increase production to
100,000 tonnes a year.
Coil transport at the Sayanal plant
Packaging materials made from aluminium foil
are in high demand all over the world. Typically,
the higher a country’s standard of living,
the higher the demand for aluminium foil for
packaging purposes. Analysts at BrookHunt
predict that by 2025 the amount of aluminium
used for packaging in developed countries
will have increased by nine million tonnes,
compared with the 2010 level of 5.5 million.
Converter foil
Converter foil is the Packaging division’s most
promising product as it delivers much higher
margins than conventional household foil.
Converter foil is used for easy storage and
packaging of goods such as food, pharmaceuticals
and cosmetics. Alufoil is the perfect material
for preserving the taste and freshness of
dairy products, juices and baked good.
Based on Rusal’s estimates, converter foil
accounts for 60% of the world market. Rusal
is planning on coupling an increase of overall
production in the Packaging division (from
81,000 to 100,000 tonnes) with a shift in distribution
to converter foil (from 30% of total
production to 50%).
Household foil
The improving economic situation in Russia
has resulted in the consumer demanding
higher standards in their basic household
goods. Russian consumers begin to prefer ecofriendly
and healthy goods to those that are
cheaper but less safe for themselves and the
environment. This trend can also be seen in
the household
packaging materials
market,
which has led
to an increasing
demand for
foil. The Russian
household
foil market has
been growing
steadily both
in scale and
volume. ‘Sayanskaya
Foil’,
produced by
Rusal, has become
the most
popular household
foil brand
© Rusal
due to its high
quality and product diversity.
Household aluminium foil strip comes in
all shapes and sizes, making it very versatile.
Depending on the foil thickness (9, 11, 14,
20 µm), it can be used for storing or preparing
food at a widevariety of temperatures.
The strip width is specially designed to fit in
standard-sized stoves. The bobbin length varies
between 8 and 100 metres.
Household foil is produced at the ‘Sayanskaya
Foil’ plant in Moscow region, while aluminium
strip comes to the factory from Rusal’s
foil mills for rolling and packaging. Then
the finished product is ready for sale. On
the B2C market segment for household foil,
Rusal’s owns proprietary trademarks ‘Sayanskaya’
and ’Sayana’. Under the brand name
‘Sayana’, Rusal offers cling film, baking paper
and roasting sleeves and foil for hairdressers.
Rusal, according to in-house analysts,
accounts for more than 50% of the domestic
household foil market. Not only does Sayanskaya
Foil make its own products, it also
provides custom labels for world-famous retail
brands operating in Russia.
Rusal’s production facilities
The Sayanal plant is the most technologically
advanced of Rusal’s foil mills. It is located
next to the Sayanogorsk and Khakas aluminium
smelters. Sayanal was built in 1993 with
the support of the Italian engineering company
Fata and the US company Reynolds Metals.
This is Rusal’s sole foil mill which produces
decorative foil, laminates, paperbacks, multicoloured
prints, lacquer coating and colouring.
Sayanal’s design team customises foil to fit the
clients’ needs.
Between 2008 and 2010 the plant started
producing new kinds of foil and packaging materials:
plain 5 µm foil for capacitors, a special
aluminium strap for the production of wainscotings,
multilayer composite foil for sealing
food products and coloured paper-backed foil
for the tobacco industry. In 2011 Sayanal
produced a small amount of foil (4.5 µm) for
a Russian capacitor factory; 4.5 µm is Rusal’s
thinnest foil at present.
Rusal is implementing a multi-faceted facility
upgrade at Sayanal to increase the plant’s
capacity from 38,000 to 42,000 tonnes a year
and also improve product quality. In September
2011, the thickness gauge for mill B1 was
replaced, and the thickness monitoring system
and strip profile were upgraded. An upgrade
of the C32 mill finish is planned for 2014.
The foil mill Ural Foil will increase production
levels from 16,000 to 24,000 tonnes a
year. This plant is an important pillar of Rusal’s
packaging business and one of the fastest
growing facilities in Russia. Ural Foil was built
in 2003 as part of Mikhailovsk non-ferrous
metal working plant.
The direct rolling mill ABP 1600 was upgraded
and commissioned in 2013. Planned
plant upgrades include: debottlenecking in
the casting blank production area; modernising
the cutting machine and equipping it with
a lubrication unit for container foil production
and purchase of a foil annealing furnace; retrofitting
of the direct casting unit ABP 1600;
purchase of a modern cutting machine for foil
with a thickness of 0.005-0.05 mm; and the
purchase of two foil annealing furnaces.
The management is also planning to conduct
a partial upgrade of the automatic process
control system for the Quatro 1800 roughing
26 ALUMINIUM · 11/2013

SPECIAL
ALUMINIUM RoLLINg INDUSTRY
mill and Achenbach foil mills. In the next two
years a new gas engine generator plant (14
MW) is to be constructed at Ural Foil. For
consumers in aviation, construction and the
electrical and pharmaceutical industries, the
company recently introduced a new product:
foil, 0.12-0.18 mm in thickness, which is used
for the production of heat exchangers and automotive
radiators.
Rusal’s foil mill Armenal is the sole foil producer
in the Caucasus and Central Asia, and
one of the most modern and ‘green’ mills in the
world. It was built in May 2000 as part of the
Kanaker aluminium smelter. Achenbach from
Germany carried out upgrades to the facility
from 2004 to 2006: the installation of latest
equipment allows Armenal to provide for the
full production process on its premises,
diversify its products and ensure the
highest quality of its goods.
In 2009 the factory began production
of household foil (12-22 µm),
which is in high demand globally. Soon
the plant will work on further mastering
thin foil technology. In 2010 the foil
mill deployed a new machine for foil
cutting and bifurcating and installed a
new Seco / Warwick furnace. The new
equipment contributes to further improve
the quality of Armenal products.
In order to increase efficiency, the
management plans to install an Achenbach
system in 2013-2014, which will
capture and distill fumes as well as generate
Airpure-Wor lubricating and cooling
liquid. The smelter will be equipped
with an additional transformer substation
and cooling towers. In the cutting
and annealing works the cutting machine
will be upgraded and equipped with a
lubrication unit for the production of
container foil. The packaging area will
receive a new chamber for timber drying.
Armenal’s production is set to rise from
26,000 to 33,600 tonnes a year, on par
with the overall increase at the Packaging
division.
Sayanskaya Foil was founded in
1997 in order to utilise foil waste from
Rusal’s Sayanal foil mill. Two years later
it was relocated to the Moscow region
to streamline logistics and enhance customer
relations. All the equipment at
Sayanskaya Foil was supplied by Ludwig
Brucher from Germany.
Since 2010 Sayanskaya Foil has been
working to increase production capacity
and improve product quality. Upgraded
equipment along with operational
standardisation have led to an increase
in production from 16,000 to 23,000 unites
per machine.
Since its inception, Sayanskaya Foil’s
product range has increased five-fold, and
its output has increased by 40 times. Year after
year the company broadens its product range
by 1-2 products. Last year plant production
reached almost 2,600 tonnes; this year output
is expected to grow by 7.5%, reaching 2,800
tonnes. Sayanskaya Foil has a yield ratio of
99.6%, making it a highly efficient facility.
Technology centre
In June 2011 a technology centre in Sayanogorsk
was founded under the auspices of
Rusal’s Packaging division. The centre is focused
on finding solutions to issues related to
standardising foil production, consolidating
and analysing data, selecting and implementing
the best methods and professionally training
employees at Rusal’s foil mills. The centre
also tests new technologies and works on its
further implementation at Rusal’s facilities.
All of Rusal’s foil mills can gain certifications
in accordance to international quality
and environmental standards thanks to the
technology centre’s work. These ‘umbrella’
certificates help limit the company’s audit expenses
and monitor product quality. Today,
all of Rusal’s Packaging division facilities are
certified in accordance to the ISO 9001 international
quality standards.
n
Millmate Thickness Gauge. Lab accuracy
in the mill.
With more than 150 installations worldwide the MTG has shown its reliability and
exceeded our customers’ expectations. The green PEC measurement technology
is environmentally-friendly, providing personal safety and totally eliminating the
hazardous drawbacks of systems based on isotope or X-ray sources.
MTG works impeccably in the toughest of environments and there is no need for
calibration and alloy compensation inherent in older technologies.
MTG is more than a thickness gauge and has several extra features including reliable
clad measurement and a unique on-line measurement of electrical resistivity.
www.abb.com/pressductor
ALUMINIUM · 11/2013
ABB AB
Force Measurement
Phone: +46 21 32 50 00

ALUMINIUMwALzINDUSTRIE
KunShan Aluminium erhöht 6-µm-Folienproduktion auf 40.000 Jahrestonnen
Achenbach punktet mit integrativer Technologie
Der integrative Ansatz, den Produktionsprozess
anlagenübergreifend zu optimieren,
hat auch KunShan Aluminium
überzeugt. Aluminium­Folienwalzwerkanlagen
und Folienschneidmaschinen aus
einer Hand zu entwickeln und zu vertreiben,
ist weltweit einzigartig und von
großem Nutzen für die Anlagenbetreiber.
Denn auf diese Weise können Verbundeffekte
im Sinne einer OEE (Overall
Equipment Efficiency) realisiert werden,
die gleichzeitig höchste Produktivität und
beste Qualität der Endprodukte gewährleisten.
KunShan Aluminium increases 6 µm foil production to 40.000 tpy
Achenbach scores with integrated technology
Die Entscheidung, in der Ausbaustufe 2 ihres
Werkes in KunShan City Achenbach nicht
nur erneut als Lieferant eines weiteren 2.000
mm breiten Folienfertigwalzwerkes auszuwählen,
sondern darüber hinaus auch in Bezug
auf die Folienschneidtechnik auf Achenbach
Optifoil umzusteigen und auch den
neuen Separator bei Achenbach zu bestellen,
hat einen Grund: Man ist mit den vor sechs
Jahren an AKS KunShan Aluminium Co.,
Ltd. in Kunshan in der chinesischen Provinz
Jiangsu gelieferten drei 2.000 mm breiten
Achenbach-Folienwalzwerken, die allesamt
mit der Optiroll-Automatisierungstechnik und
Optipure-Verfahrenstechnik ausgerüstet sind,
sehr zufrieden. Beim großen Festakt zur Einweihung
der neuen Produktionsstätte 2007
hatte man Achenbach unter Anwesenheit von
Repräsentanten der Provinzregierung Jiangsu
bereits sowohl für die
hervorragende Qualität
der gelieferten
maschinellen Ausrüstung
als auch für
die große Termintreue
gelobt. Dieser
erste gute Eindruck
hat sich in den Folgejahren
des hochproduktiven
Anlagenbetriebs
bestätigt.
Der Markterfolg
mit erstklassiger
6-µm-Aluminiumfolie
und die große
Zufriedenheit mit
dem Achenbach-Maschinenpark
hatten
KunShan Aluminium
im letzten Jahr be-
2.000 mm breites Aluminium-Folienwalzwerk für Fertigdicken bis 6 µm
2,000 mm wide aluminium foil rolling mill for finish thicknesses of up to 6 µm
Also KunShan was convinced by the integrative
approach to optimise the production
process in a cross­system approach
(rolling mills and slitting machines). To
develop and to market aluminium foil
rolling mills and foil slitting machines
all from a single source is a world­wide
outstanding characteristic and a great
benefit for the plant operators. In this
Optifoil-Separator für Fertigrollendurchmesser bis 1.000 mm
Optifoil Separator for finish roll diameters of up to 1,000 mm
way, synergy effects in the sense of an
OEE (Overall Equipment Efficiency) can
be realised to simultaneously guarantee
highest productivity and best quality of
the finished products.
The decision to select Achenbach not only
again as supplier for another 2,000 mm wide
foil finishing rolling mill in the second expansion
stage of their
premises in Kun-
Shan City but also to
change their slitting
technology to Achenbach
Optifoil and to
order the new separator
from Achenbach,
has got one reason.
The customer is
highly satisfied with
the three 2,000 mm
wide foil rolling mills
delivered to AKS
KunShan Aluminium
Co., Ltd, Kunshan,
Jiangsu province in
China – all of them
equipped with Optiroll
automation technology
and Optipure
© Achenbach
28 ALUMINIUM · 11/2013

SPECIAL
ALUMINIUM RoLLINg INDUSTRY
Aufwicklung mit Option zur Nachrüstung mit
einem Pinhole Detector / Rewinder with option to
retrofit a pinhole detector
media systems: during the official ceremony
for inaugurating the new production site in
2007, Achenbach was commended for the
high-class quality of the delivered machinery
wogen, ihre Kapazitäten mit einem weiteren
Folienwalzwerk und Separator auszubauen.
Beides, Walzwerk und Separator, sind in der
Zwischenzeit termintreu geliefert, in Betrieb
genommen und abgenommen worden.
Neben der Chance, Verbundeffekte einer
anlagenübergreifenden Prozessoptimierung
zu nutzen, gab es in Bezug auf den Separator
dabei einige technische Detaillösungen, die
den Kunden von der Optifoil-Folienschneidtechnologie
überzeugten:
• angetriebene Walzen mit großem Durchmesser
bei engem Walzenabstand für eine
ideale Bahnführung
• verfahrbare Aufwicklung für eine gleichbleibende
Materialaufwickelgeometrie und
eine über den Durchmesser der Fertigrollen
hinweg konstante Wickeldichte
• gewichtsausbalanciertes Kontakt- / Andrucksystem
sowie Einbau von Kraftmesslagern
in die Lagerstellen für beste Wickelergebnisse
• eine in Portalbauweise ausgeführte Fertigrollenentnahme
für deutlich kürzere Fertigrollenentnahmezeiten;
ein auf Flurebene
verfahrbares Handling kann damit entfallen,
die Nachrüstung mit einem führerlosen Transportsystem
ist problemlos möglich
• ein Leerspulenhandlingkonzept, das die
Abrollung sehr nahe an der Einlaufwalze
anbringt und so minimale Materialförderstrecken
ermöglicht
• ein Walzenwechselkonzept, das den schnellen
Wechsel von Kontakt-, Auflage- und
Stützwalzen erlaubt
• die grundsätzliche Option zur Nachrüstung
mit einem Pinhole Detector zur Qualitätssicherung
• modernste Antriebstechnik, hier mit zwei
Motoren pro Wickelebene für einen besonders
großen Regelbereich des Wickelzuges.
Das neue Walzwerk ist mit neuester Optipure-Verfahrenstechnik
und mit dem kompletten
Paket an Optiroll i2 Automatisierungssystemen
von Achenbach ausgerüstet. Äußerlich
den Systemen aus 2007 sehr ähnlich,
war KunShan Aluminium von den inzwischen
in der Optiroll-Automatisierung implementierten
modellbasierten Reglern beeindruckt.
Hierbei handelt es sich um Modelle, die den
aktuell vorliegenden Betriebszustand des
Walzwerkes erfassen und daraus online-opti-

ALUMINIUMwALzINDUSTRIE
Betreibermannschaft des Optifoil-Separators
mierte Reglerparameter ermitteln, die zu einer
deutlich besseren Bandplanheit und engeren
Banddickentoleranzen führen.
Grundsätzlich zeichnen sich auch das neue
Folienwalzwerk und der neue Optifoil-Separator
wie alle Maschinen und Anlagen von
Achenbach durch folgende Vorzüge aus, die
den hohen Qualitätsstandard bzw. die Marke
Achenbach weltweit letztlich mit begründet
haben:
• beste Qualität aller Einzelkomponenten
• energiesparendes, emissionsminimiertes
Anlagendesign
• sehr gute Wartungsfreundlichkeit
durch eine auch daraufhin optimierte
Abrollung mit Leerspulenhandling
Operator team of the Optifoil Separators
modulare Bauweise
• große Bedienungsfreundlichkeit durch
ergonomisch optimal gestaltete Visualisierung
der laufenden Prozesse
Die Verfügbarkeit der Maschinen und Anlagen
liegt mit weit über 95 Prozent deutlich
über dem Durchschnitt. Um diese auch langfristig
halten zu können, bietet Achenbach
seinen Kunden über die gesamte Betriebsdauer
hinweg ein breites Spektrum an Serviceund
Supportleistungen an, das flexibel an die
Erfordernisse der Kunden angepasst werden
kann.
„Wir sind sehr zufrieden mit der Zusammenarbeit
mit Achenbach. Alle Fragen an
Achenbach wurden
schnell beantwortet
und zeugten von einer
großen Flexibilität im
Projektmanagement.
Auf diese Weise konnte
das gesamte Projekt in
der kürzest möglichen
Zeit realisiert werden.
Darüber hinaus danken
wir Achenbach für die
kompetente Beratung
in schwierigen Fragen
der Ablauforganisation,
wie die mit diesem
Projekt verbundene
Ausweitung unserer
Folienproduktion
ohne Beeinträchtigung
des laufenden Produktionsprozesses
zu realisieren
sei. Nicht zuletzt
herzlichen Dank
an alle Achenbach-
Mitarbeiter hier vor
Unwinder with empty spool handling
equipment as well as for their high adherence
to the schedules – in the presence of representatives
of the Jiangsu province government.
This good first impression was confirmed over
the next years of the highly productive machinery
operation.
The market success with first-class 6 µm
aluminium foil and the great satisfaction with
the Achenbach machinery induced KunShan
Aluminium last year to extend their capacity
by purchasing another foil rolling mill and a
separator. Both, rolling mill and separator,
have been delivered, commissioned and accepted
right on time.
Apart from the chance to use the synergy
effects of a comprehensive process optimisation,
there were several technical detail solutions
regarding the separator. These details
convinced the customer to order the Achenbach
Optifoil technology:
• driven rolls with big diameters at narrow
roll distances and ideal strip guiding
• shiftable rewinder for a constant material
rewinding geometry and a constant winding
density even beyond the diameter of the finish
rolls
• weight-balanced contact / pressure system
as well as installation of load bearings into
the bearing spots for best winding results
• portal design of finish roll removal device
for considerably shorter finish roll removal
times; a handling system shiftable on floor
level can thus be omitted, the upgrade with a
pilotless transport system is possible without
any problems.
• empty spool handling concept, which applies
the unwinder very close to the entry
roll to facilitate minimum material transport
ways
• roll changing concept, which allows the
quick change of contact, application and backup
rolls
• all preparations to upgrade the separator
with a pinhole detector for quality assurance
• highly modern drive technology, here with
two motors per winding level for a very extended
winding tension range.
The new rolling mill is equipped with the
latest Optipure media systems and with the entire
package of Optiroll i2 automation systems
made by Achenbach. Outwardly resembling to
the systems of 2007, KunShan Aluminium was
very impressed by the model-based controllers
which have been implemented in the Optiroll
automation systems in the meantime. These
are models, which record the current operating
condition of the rolling mill and hence calculate
online-optimised controller parameters,
which result in a considerably improved both,
strip flatness and strip thickness tolerances.
30 ALUMINIUM · 11/2013

SPECIAL
Basically the new foil rolling mill and the new Optifoil Separator
– such as all Achenbach machinery and systems – are characterised
by the following advantages, which have established the high quality
standard and therefore the brand name Achenbach on the worldwide
market: best quality of all single components • energy-saving
and emission-minimised machinery design • very good maintainability
by optimised modular design • high operator convenience by
ergonomically and perfectly designed visualisation of the running
processes. The availability of the machinery and systems is with 95%
far beyond the average. In order to maintain this even on the longer
term, Achenbach offers a wide variety of service and support packages
throughout the entire operating time, which can be flexibly
adapted to the customers’ requirements.
“We are very satisfied with the good collaboration between
Achenbach and ourselves. All questions were answered quickly and
proved Achenbach’s flexibility in project management. Thus, the
entire project could be realised in shortest possible time. Moreover,
we are very thankful for Achenbach’s advice how to extend our
foil production with only very few impact on the running operation.
Many thanks to all Achenbach supervisors for their close cooperation
during installation and commissioning. Great job!” says Yuan
Bisheng, project manager at Kunshan.
Take Note –
Saws worth noting
Innovative
bandsaw
technology for
efficient cutting
performance
Betreibermannschaft des neuen Aluminium-Folienwalzwerks
Operator team of the new aluminium foil rolling mill
The excellent cooperation was highly appreciated by Achenbach:
“The professional project management of KunShan Aluminium in
this challenging project enabled a nearly perfect processing: the site
was perfect-ly prepared for starting the on-site assembly, the reliability
of the customer during assembly and commissioning was
very high and smaller bottlenecks, which may happen on each site,
were always eliminated mutually, unbureaucratically and quickly,”
says Jörg-Michael Hey, head of the order processing department
and Daniela Posselt as project manager regarding the cooperation
with the customer.
The great cooperativeness of the KunShan staff is emphasised by
the assembly and commissioning team: “It was a really pleasant site,
which we were all very fond of.” And Wilhelm-Friedrich Sommer,
responsible for the Technical Purchase Department, stresses: “By
means of this project, the good business relation between KunShan
Aluminium and Achenbach Buschhütten was confirmed once again.
We are glad to have KunShan Aluminium, a premium foil producer,
as our customer, who decided for Achenbach as machinery supplier –
with technical ambition and enthusiasm for most modern technology.
We would be very grateful if we could support KunShan Aluminium
with our service and machinery extension even in the future.” ■
ALUMINIUM · 11/2013
www.moessner-kg.de,
post@moessner-kg.de
phone: +49 7175 998060
· Design and Production
Made in Germany
· Reduced cutting tolerance
· Long tool life due
to vibration restistant
construction
· Reduced consumption
of lubricate due to
innovative control of
spray stream

ALUMINIUM RoLLINg INDUSTRY
Ort für ihre große Kooperationsbereitschaft
während der Montage und Inbetriebnahme.
Great job!“, so Yuan Bisheng, Project Manager
bei Kunshan.
Die exzellente Zusammenarbeit wird auch
seitens Achenbach gelobt: „Das professionelle
Projektmanagement von KunShan Aluminium
in diesem ehrgeizigen Projekt hat eine
nahezu reibungslose Abwicklung möglich gemacht:
Die Baustelle war für den Start der Vor-
Ort-Montage perfekt vorbereitet, die Zuverlässigkeit
des Kunden während der Montage
und Inbetriebnahme hoch, und kleinere Engpässe,
die es auf einer Baustelle nun einmal
immer mal wieder gibt, wurden stets unbürokratisch
und schnell gemeinsam behoben“, so
beschreiben Jörg-Michael Hey als Chef der
Auftragsabwicklung und Daniela Posselt als
Projektmanagerin die Zusammenarbeit.
Montage- und Inbetriebnahme-Team unterstreichen
ihrerseits die große Hilfsbereitschaft
der KunShan-Mitarbeiter: „Dies war eine angenehme
Baustelle, die richtig Spaß gemacht
hat.“ Und Wilhelm-Friedrich Sommer, gesamtverantwortlich
für den technischen Vertrieb,
betont: „Mit diesem Projekt wurden die
guten Geschäftsbeziehungen zwischen Kun-
Shan Aluminium und Achenbach Buschhütten
ein weiteres Mal bestätigt. Wir freuen uns,
mit KunShan Aluminium einen Premium-
Folienproduzenten als Kunden zu haben, der
sich mit technischen Ehrgeiz und Begeisterung
für moderne Technologie für Achenbach als
Anlagenlieferanten entschieden hat. Wir würden
uns sehr freuen, wenn wir ihm auch in
Zukunft in Anlagenservice und Anlagenausbau
zur Seite stehen dürfen.“
n
The Royal Mint: Siemens VAI implements optimal
upgrade path for the legacy automatic gauge control
M. Chatterton, Siemens VAI
The roots of Siemens VAI as it stands today,
as part of Siemens Plc’s Industry Sector, lead
back to the Davy business who, during the
1980s and 1990s installed many Automatic
Gauge Control (AGC) / Automatic Flatness
Control (AFC) systems on cold mills using
their System 2, 21 and KS2100 platforms.
With advances in technology, support for
these platforms is no longer guaranteed due
to equipment obsolescence. As such producers
are reliant on in-house spares and know-how
to maintain the systems, and are therefore
susceptible to excessive downtime if a breakdown
occurs in these systems.
Stuart North, project manager at Siemens
VAI, comments: “This was the situation facing
the Royal Mint on their single stand cold
reversing mill at Llantrisant, Wales. Davy Mc-
Kee had installed a System 21 AGC on the mill
in the mid-1990s and had continued support of
the system through a service contract with Siemens.
After a significant breakdown in 2011,
it was evident to both The Royal Mint and Siemens
that the system had to be replaced.”
According to Stuart, the objectives of the
upgrade project were to
• replace the existing System 21 automatic
gauge system and main DC drives (mill,
coiler, un-coiler) with a cost effective
solution which would minimise downtime
• identify any other major components
which should be replaced either due to
obsolescence or to provide either
improved performance or an optimum
solution
• obtain at least the equivalent thickness
tolerances as achieved with the existing
System 21
• deliver the equipment within nine
months and install and start-up the mill
within a 10 day shutdown.
The new AGC system was based on the latest
Siemens VAI Siroll Alu TCS which is based
on the Siroll suite of software and system solutions.
The hardware backbone is the high
performance Simatic TDC system.
The system includes all the features typically
needed for a cold mill application to optimise
the rolling operation:
• AGC for narrow strip thickness tolerances
• Stand controls for closed loop control of
the mill actuators
• Intelligent pass schedule editor and storage
© Siemens
Siroll Alu TCS Cabinet
Siroll Alu TCS – pass scheduling editor and storage
32 ALUMINIUM · 11/2013

Modern logistics
systems
By logistics systems we mean the purposeful combination
of individual functions, i.e. transport, storage, packaging
and marking, to form one whole – the logistics in your
rolling mill or finishing plant.
Logistics planning based on studies and simulation
models
Transport and handling systems for heavy loads
Fully automatic flat and high-bay storage systems
Warehouse management and manufacturing
execution systems
Packaging and strapping machinery for coils,
sheet packs and slit coils
Marking systems for coils, metal sheets, slabs and pipes
High-pressure grinding machines for slabs, billets
and blooms
SMS LOGISTIKSYSTEME GMBH
Obere Industriestrasse 8 Phone: +49 2738 21-0 E-mail: info@sms-logistics.com
57250 Netphen, Germany Fax: +49 2738 21-2222 Internet: www.sms-logistiksysteme.com

ALUMINIUM RoLLINg INDUSTRY
Siroll Alu TCS – typical operators display
• Mill calibration and hysteresis test
sequences.
An integrated package of support functions includes
everything required for an economical
system that is easy to operate and maintain:
• Engineering station with all necessary
tools (Simatic Manager)
• User-friendly HMI based on WinCC
• Message, alarm and diagnostic system
• Data recording and analysis system – PDA
• Logging functions for the generation of
production reports
• Remote access functionality to allow
Siemens support directly to the target
system.
The replacement drives were from the new
Sinamics DCM DC drives range.
The overall success of the upgrade depended
on many factors. Stuart further comments:
“To minimise installation time and reduce
cost, Siemens provided a ‘plug and play’ philosophy
in design of the Siemens Alu TCS.
This enabled the existing field devices, interfaces
and cabling to be retained.”
Siemens VAI also offered the Royal Mint,
pre-shutdown training at the company offices
in Sheffield, in order to test and develop the
system to suit their tailored requirement.
Training was performed with both operators
and maintenance engineers to optimise the
mill start-up which was successful, enabling
full production within 14 days from shutdown
to hot commissioning. Improved thickness
tolerances on products were established
within days of start-up and downstream processes
were providing feedback on the product,
which were used to develop the system further
as well as give specific training on quality
monitoring.
Final acceptance was achieved ahead of the
planned schedule.
Overall for both the Royal Mint and Siemens
the project was a big success. Tony
Baker (head of Engineering) from the Royal
Mint comments: “Our upgrade objectives
were met and exceeded in some cases. We
have benefited by having a new, supportable
automation system which is maintainable by
our engineers.”
The project has reduced the risk to the availability
of the rolling mill and future proofed
the system for the medium to long term.
Maintenance time and downtime have been
reduced and the customer is now producing
improved quality of feed stock for their final
products, to maintain their position as world
leader. Siemens VAI have implemented and
proven an optimal upgrade path for their legacy
AGC systems and look forward to maintaining
a long established relationship with the
Royal Mint.
Author
Mark Chatterton is director of Aluminium at Siemens
VAI Metals Technologies.
34 ALUMINIUM · 11/2013

Focus on Precision, Yield and Green
Set the benchmark in Aluminum Rolling!
siemens-vai.com
We know what we’re talking about when it
comes to aluminum rolling.
During the past five decades we have
supplied hundreds of new and modernized
mills that set the benchmark for producing
quality strip in an efficient manner. The
market is ever changing and now demands
highest yield and tolerances while
minimizing environmental impact.
Siemens VAI is at the forefront of this
challenge.
On the basis of immense process knowhow
and engineering experience,
Siemens VAI works with our customers to
meet their targets for productivity, quality,
yield and flexibility.
As a total solution provider, maximum mill
performance is assured with the latest
equipment design, advanced technological
packages, sophisticated electrical,
automation, environmental systems, and a
full range of vertically integrated supply
packages. With specialized technologies for
thickness, profile and flatness control, the
strictest quality and tolerance demands are
met for all downstream product
requirements.
At every stage of a mill’s productive
lifetime, we have the right solution to
ensure that your mill performs at its peak
level. Our portfolio includes:
• New plants and mill modernizations
• Complete equipment supply
• Electrical and automation systems
• Consultancy services and mill audits
• Customized mill products
• Worldwide, around-the-clock services
Be the leader in the field – with SIROLL
ALU solutions from Siemens VAI, a
global supplier but your local partner.
Answers for industry.

ALUMINIUM RoLLINg INDUSTRY
Kobe Steel to set up factory in China for aluminium sheet
Kobe Steel, Ltd is to establish a company
in the Xiqing Economic­Technological
Development Area in Tianjin, China, to
produce aluminium sheet for automotive
body panels. The new company –
Kobelco Automotive Aluminum Rolled
Products (China) – will be the first Japanese
operation to produce this kind of
product in China. Kobe Steel will supply
master coils from its Moka Plant in Tochigi
Prefecture, Japan. The coils will then
undergo annealing followed by surface
treatment and other finishing processes
by Kobelco Automotive.
The new company will be established in early
2014. It will have a production capacity of
100,000 tonnes a year. Total investment will
amount to 1.15 billion yuan (about 19bn yen,
or USD 195m). The plant is expected to start
production in 2016, and will employ about
140 people when it goes into full operation.
Kobe Steel began supplying aluminium
sheet for automotive body panels to Japanese
automakers in the 1980s. It has built up a
strong supply performance history mainly on
the Japanese market, with a market share now
of over 50 percent. In addition to developing
alloys and production technologies, including
heat treatment, the company provides technical
solutions on shape design and forming suitable
for aluminium applications. Kobe Steel
has received high acclaim not only from Japanese
carmakers, but also from European and
US carmakers.
Kobe Steel currently supplies the Chinese
market from its Moka Plant. However, carmakers’
strong requests for a local source of
automotive aluminium sheet led to the decision
to set up a factory in China.
China is the world’s largest automobile
market. In the next ten years, car production
is expected to increase by about 50 percent.
Stricter fuel efficiency regulations in China
aim to control the serious air pollution problem.
As developing lighter vehicles is strongly
required, demand for aluminium sheet is anticipated
to increase tremendously in China in
the coming years.
Kobe Steel’s Aluminium & Copper business
is focusing on the automotive sector, which
is increasing the use of aluminium to make
lighter cars. In June, the company entered
into a cooperation agreement with Germany’s
Hydro Aluminium Rolled Products GmbH for
aluminium sheet technologies for automotive
body panels. Following this, Kobe Steel’s plan
Aerial view of the Moka Plant
to establish a base in China will strengthen its
technical network for the growing demand for
this kind of product.
For aluminium forgings used in automotive
suspensions, the company formed Kobe
Aluminum Automotive Products in the United
States already ten years ago. Kobe Steel subsequently
formed Kobe Aluminum Automotive
Products (China) in September 2010 to
make the same products in China. Kobe Steel
now has a production network covering three
Aluminium coils at the Moka Plant
countries – Japan, the US and China – for this
product.
For extrusions and fabricated products,
including bumper reinforcement parts, Kobe
Steel and Sapa entered into a technical transfer
agreement for Kobe Steel to supply Sapa
with production technology for high-end aluminium
extrusions. In this way, Kobe Steel is
building a global supply network for its extrusions
through Sapa’s worldwide locations. n
© Kobe Steel
36 ALUMINIUM · 11/2013

ALUMINIUMwALzINDUSTRIe
Hochgeschwindigkeitsschneidanlagen
erfordern anspruchsvolle Messtechnik
D. Neumann, Josef Fröhling GmbH & Co. KG; K. Christofori, Micro-epsilon Optronic GmbH
Aluminiumband und -folie erfreuen sich
weltweit einer stetig steigenden Nachfrage.
Immer höhere Bundgewichte bei
geringeren Dicken bedingen steigende
Bandlängen und damit größere Anlagenlaufzeiten.
Der Kostendruck in der
Produktion führt zu neuen anlagentechnischen
Innovationen. Die schnellsten
Schneidanlagen baut Danieli Fröhling
und erreicht bei Besäumscheren bisher
Bandgeschwindigkeiten von max. 1.800
m/min. Das verlangt ein nahezu perfektes
Zusammenspiel von Mechanik, Steuerungstechnik
und Sensorik. Mit welchen
technischen Neuerungen der Maschinenbau
auf die hohen Qualitätsforderungen
der Aluminiumindustrie reagiert und dabei
die hohe Präzision optischer Messverfahren
nutzt, zeigt nachfolgender Beitrag.
High-speed slitters demand
sophisticated measuring techniques
D. Neumann, Josef Fröhling GmbH & Co. KG;
K. Christofori, Micro-epsilon Optronic GmbH
Die weltweite Aluminiumproduktion wächst
rasant von Jahr zu Jahr. Berücksichtigt man
sämtliche bisher produzierten Aluminiummengen
der letzten 114 Jahre, so entfallen ein
Drittel allein auf das letzte Jahrzehnt. Einen
entscheidenden Anteil an diesem Wachstum
hat China. Die Herstellung von Primäraluminium
wächst in China jährlich um 25 bis 33
Prozent. Damit liegt China mit einem Viertel
der Weltjahresproduktion an der Spitze (zum
Vergleich: Europa und USA je 12%). Betrachtet
man die wachsende Industrialisierung als
treibende Kraft dieser Wachstumsdynamik,
dann sind die Konsumprozesse, deren Anteil
im Vergleich zu den entwickelten Industriestaaten
noch sehr gering ausgebildet sind, ein
zukünftiges Wachstumspotenzial.
Doch gerade das stetig steigende Produktionsaufkommen
stellt besonders hohe Anforderungen
an die Investitionen in Neuanlagen
und damit auch an die Unternehmen des Maschinenbaus.
Noch vor zehn Jahren betrug das Bundgewicht
eines typischen Coils zehn Tonnen
bei einer üblichen Breite zum Walzen, Besäumen
bzw. Längsteilen zwischen 1.400 mm
und 1.600 mm. Heute fordern die Kunden
für neue Anlagen Linienbreiten von 2.100 bis
2.300 mm, in Einzelfällen sogar 2.600 mm
bis 2.800 mm mit einem typischen Bundgewicht
von 30 bis 35 Tonnen. Das wirkt sich
bei Schneidanlagen (Abb. 1) entscheidend auf
die Auslegungskriterien für Geschwindigkeit,
Abb. 1: Hochleistungsspaltanlage mit Vakuumrolle und Messerwechseleinrichtung
Fig. 1: High-performance slitter with vacuum roll and cutter-changing device
Aluminium strip and foil are enjoying a
steady rise in demand worldwide. Ever
greater coil weights coupled with smaller
thicknesses are resulting in greater strip
lengths and thus greater strip-processing
times. Cost pressures on the production
side are leading to new innovations in
plant technology. Danieli Fröhling supplies
the fastest cutting machines and has
so far achieved maximum strip speeds
of 1800 m/min with trimming shears.
Such speeds demand an almost perfect
interplay between the mechanics and
the control and sensor technologies. The
following article describes the technical
innovations that mechanical engineers
are using in response to the high quality
demands of the aluminium industry and
the high degree of precision of the optical
measuring techniques involved.
The production of aluminium worldwide is
growing rapidly year by year. If one considers
all of the aluminium that has been produced
in the past 114 years, one third is attributable
to the past decade alone. China is responsible
for a significant share of this growth. The
production of primary aluminium in China is
growing at a rate of 25 to 33 percent a year.
China is thus the leading producer, with a
quarter of global production (for comparison:
Europe and the USA each account for 12%).
If one takes into account that the driving force
for this dynamic growth is growing industrialisation,
consumer demand offers potential for
future growth given that thus far it has only
developed to a very small extent in China compared
with industrialised countries.
The continual increase in the quantities being
produced is presenting particularly great
demands with respect to investments in new
plant, and thus on mechanical engineering
companies as well.
Even as recently as ten years ago the weight
of a typical coil was ten tonnes and the usual
width for rolling, trimming or slitting was
between 1,400 and 1,600 mm. Nowadays,
customers for new plants are demanding line
© Danieli
38 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM ROLLING INDUSTRY
widths of 2,100 to 2,300 mm, in individual
cases even 2,600 to 2,800 mm, with a typical
coil weighing 30 to 35 tonnes. This is having
a decisive influence on the design criteria for
slitting lines with regards to speed, productivity
and material tolerances (Fig. 1).
In slitters or edge-trimming lines operating
continuously and with long strip-processing
times, it is absolutely essential to achieve continuously
repeatable and precise cuts over a
long period of time or for as many coils as possible.
Not only is the width tolerance of great
importance but also the need for a consistently
good edge quality over the whole length of
the strip. On top of this, converters want ring
diameters that are as large as possible but still
perfectly coiled in order, for example, to carry
out stamping or deep drawing operations with
their ever-tighter tool tolerances with as few
stoppages as possible.
The trend is the other way round with finished
products. Here, attention is increasingly
being given to reducing weight and to miniaturisation
– regardless of whether it is a mobile
phone, a laptop or a motorcar. The demand for
thinner strip is increasing accordingly. Given
the increase in coil weight and reduction in
strip thicknesses, this ultimately means an increase
in the processing time for a coil in a unit.
However, because demand is also increasing
at the same time, this means is becoming evermore
important to have greater operating
speeds and reduce stoppages and outages.
This demands an almost perfect interplay
between the mechanics and the control and
sensor technologies.
Optimisation of the circular-cutter design
The depth of penetration of the cutter is one of
the main parameters when it comes to achieving
an excellent cut quality. The optimal depth
of penetration depends on the material properties
themselves as well as on the strip thickness.
The actual depth of penetration is a function
of the actual cutting force and the machine
rigidity. The deflection of the knife shafts
represents a significant part of the overall rigidity.
If a number of circular knives are mounted
on a cutter shaft, the depth of penetration of
each individual knife is determined by the axial
position of the knife. The deflection of the
cutter shafts can be reduced considerably by
reducing the spacing of the cutter shaft bearings,
by using high-precision bearings and by
generally optimising the whole bearing system
(Fig. 2).
Danieli Fröhling optimises existing machine
parts using a sophisticated finite element
analysis (FEA) followed by verification
Produktivität und Materialtoleranzen aus.
Bei kontinuierlichem Betrieb und großen
Bandlaufzeiten in den Längsteil- oder Besäumanlagen
ist es absolut notwendig, ständig wie-
Fig. 2: Cutter shaft with different cut widths
derholbare und präzise Schnitte über einen
langen Zeitraum bzw. möglichst viele Bunde
zu erreichen. Dabei ist nicht nur die Breitentoleranz,
sondern vor allem auch die konstante
Kantenqualität (Schnittgrad) über die
gesamte Bandlänge von hoher Bedeutung.
Dazu kommen Wünsche der Endverarbeiter
nach möglichst großen Ringdurchmessern mit
perfektem Wickelbild, um zum Beispiel Stanzoder
Tiefziehprozesse mit den auch dort immer
enger werdenden Werkzeugtoleranzen
möglichst selten zu unterbrechen.
Umgekehrt ist der Trend bei den Fertigprodukten.
Hier wird immer mehr auf geringeres
Gewicht und Miniaturisierung geschaut – egal
ob beim Handy, Laptop oder Automobil.
Entsprechend steigt der Bedarf an dünneren
Bändern an und damit steigen letztlich bei
großen Bundgewichten und geringeren Banddicken
die Laufzeiten eines Bundes auf einer
Anlage. Da gleichzeitig aber der Bedarf steigt,
werden höhere Anlagengeschwindigkeiten
Abb. 3: Schneidkante (Prinzipdarstellung)
Fig. 3: Cut edge (basic principle)
und die Verkürzung von Stopp- und Nebenzeiten
immer wichtiger. Dies verlangt ein nahezu
perfektes Zusammenspiel von Mechanik,
Steuerungstechnik und Sensorik.
Abb. 2: Messerwelle mit unterschiedlichen Schnittbreiten
Optimierung der Kreismesserscherenkonstruktion
Einer der Hauptparameter für eine exzellente
Schnittqualität ist die Eintauchtiefe der
Messer. Die optimale Eintauchtiefe hängt
von den Materialeigenschaften selbst sowie
von der Banddicke ab. Die tatsächliche Eintauchtiefe
ist eine Funktion von aktueller
Schnittkraft und der Maschinensteifigkeit.
Ein wesentlicher Teil der Gesamtsteifigkeit
ist die Durchbiegung der Messerwellen. Ist
eine bestimmte Anzahl von Kreismessern auf
einer Messerwelle montiert, so wird die Eintauchtiefe
jedes einzelnen Messers durch die
axiale Position des Messers selbst bestimmt.
Durch die Reduzierung der Lagerabstände
der Messerwellenlagerungen, den Einsatz von
Hochpräzisionslagern sowie einer generellen
Optimierung des gesamten Lagerungssystems
kann eine erhebliche Verringerung der Durchbiegung
der Messerwellen erreicht werden
(Abb. 2).
Eine leistungsfähige
FEM-Analyse mit anschließender
Überprüfung
anhand von Modellversuchen
bereichert
die Optimierung vorhandener
Maschinenelemente und liefert die
Basis für den konstruktiven Erfolg bei Danieli
Fröhling. Eine Vorgehensweise, die sehr erfolgreich
umgesetzt wird und für stetig neue
Innovationen in der 65-jährigen Tradition des
Unternehmens sorgt.
➝
ALUMINIUM · 11/2013 39

ALUMINIUMwALzINDUSTRIe
Ein neuer technischer Lösungsansatz ist die
Analyse der Steifigkeit aller bestimmenden
Maschinenkomponenten. Durch die Anhebung
der gesamten Steifigkeit auf ein sehr hohes
Niveau ist es nun möglich, die Eintauchtiefe
aller installierten Kreismesser wesentlich
näher an eine optimale Position zu bringen.
Das führt zu wiederholbaren und exzellenten
Schnittqualitäten. Dies, kombiniert mit der
richtigen Schnittspaltwahl, führt darüber hinaus
zu längeren Standzeiten der Messer.
Die Entwicklung der CNC-Längsteil- und
Besäumschere stammt aus den 1990er Jahren.
Die Idee hinter dieser Entwicklung war
die Erkenntnis, den Schnitt des Bandes je
nach seinen mechanischen Eigenschaften wie
Zugfestigkeit, Dehnung und Bandgeometrie
zu optimieren. Geschnitten wird, indem die
Schneidkante des Messers nur zu einen gewissen
Teil in das Material eindringt und der
verbleibende Teil definiert bricht. Im unteren
Teil entsteht dann eine Bruchkante (Abb. 3).
Somit ergibt sich der „ideale“
Schnitt durch eine definierte Beziehung
zwischen Schneiden und
Brechen des Materials. Je näher
das Messer beim Eintauchen diese
„ideale“ Schnittkennzahl erfüllt,
desto sauberer ist die Schnittkante.
Ferner kann durch eine geringere
Eintauchtiefe des Messers die eingebrachte
Kraft reduziert werden,
die eine Materialspannung in den
Streifen verursacht.
Besonders interessant wird diese
technische Lösung für Applikationen,
bei denen Band mit speziellen
Eigenschaften (teure Legierungen,
dünnes Band, sehr breites
Band oder gar in Kombination
dünn / breit) geschnitten werden
soll. Danieli Fröhling hat hier in
den letzten Jahren eine Vielzahl
von Anlagen in Betrieb genommen,
die durch die verbesserte Scherenkonstruktion
eine exzellente Fertigungsqualität
erreichen (u. a. die
neue Dünnbandanlage bei MKM in Hettstedt
für dünnes Cu-Band bis 1.260 mm Breite, die
Längsteilanlagen bei PingAn oder Nanshan
in China für Aluminiumbänder bis 2.150 mm
Breite oder die Hochleistungs-Längsteilanlage
für Ma’aden in Saudi Arabien).
Bremsen und wickeln der Bandstreifen
Bei Längsteilanlagen für relativ viele Streifen
im Banddickenbereich oberhalb von 0,05 mm
hat sich der Einsatz einer Schlingengrube zur
Kompensation der unterschiedlichen Bandlängen
(aufgrund des Walzprofils) nach dem
Schneiden durchgesetzt (Abb. 4). Nur auf
diesem Weg ist es sinnvoll möglich, weitestgehend
gleiche Zugverhältnisse bei den einzelnen
Streifen aufzubringen und gleichzeitig
große Fertigringdurchmesser zu erzielen,
ohne einzelne Streifen zu überdehnen oder
zu fest bzw. zu lose zu wickeln.
Das Bremsen (also das Aufbringen eines
definierten Bandzuges) der Streifen erfolgte
bis vor einigen Jahren standardmäßig durch
Bandpressen, durch Bremsrollen oder sogenannte
„Belt Bridles”. Alle diese Systeme
haben den Nachteil, dass es zu einem starken
Kontakt und Reibung zwischen Bremsmedium
und Material kommt. Daraus können
Beschädigungen oder Verschmutzungen der
Bandoberfläche resultieren, die besonders bei
Bändern mit erhöhten Anforderung (Elektronikindustrie,
Dekoration, Bänder für Beleuchtungsanwendungen
u. ä.) störend sind
oder gar zum Ausschuss führen.
Abb. 4: Vakuumbremsrolle mit Blick auf die Band-Streifen in der
Schlingengrube / Fig. 4: Vacuum brake roll with slit strip in the
slack-loop pit
Danieli Fröhling hat bereits zu Beginn der
1990er Jahre die Vakuumtechnologie für
Bremsrollensysteme eingeführt und seitdem
kontinuierlich weiterentwickelt. Bei dieser
Technik wird mittels Unterdruck eine definierte
Haftreibung erzeugt, die es ermöglicht,
den notwendigen Bandzug für den Aufhaspel
aufzubringen. Dabei wird mit gezielter Nacheilung
der Rolle bezogen auf die Aufhaspelgeschwindigkeit
jeder einzelne Streifen mit
der gleichen Bremskraft beaufschlagt, jedoch
nur an der Unterseite des Bandes berührt. Der
Vorteil ist eine erheblich verringerte Gleitreiusing
model tests and thus provides the basis
for the company’s design achievements. It is
an approach that has been implemented very
successfully and ensured that the company has
continually introduced new innovations during
its 65-year history.
A new approach is to analyse the rigidity
of all the important machine components. By
affording particular attention to the overall
rigidity of the system, it is now possible to
achieve a depth of penetration for all the circular
knives installed that is significantly closer
to the optimal position. This results in cuts
that are reproducible and of excellent quality.
Furthermore, by combining it with the correct
choice of cutting gap, the service lives of the
knives can be extended.
Development of CNC slitters and trimming
shears began in the 1990s. The idea behind
this development was the knowledge that one
could optimise the cut of the strip depending
on its mechanical properties, such as tensile
strength, elongation and strip geometry. Cutting
involves the cutting edge of the knife only
penetrating to a certain depth in the material
and the remaining part fracturing in a defined
manner. The lower part then has a fractured
edge (Fig. 3).
The ‘ideal’ cut is thus a defined combination
of cutting and fracturing of the material. The
closer the knife is to this ‘ideal’ combination
on penetration, the cleaner is the cut edge.
Furthermore, a smaller depth of penetration
of the knife can reduce the applied force which
causes stress in the material of the strips.
This technical solution is particularly interesting
for applications where strip with special
properties (expensive alloys, thin strip, very
wide strip or even thin / wide in combination)
is to be cut. Danieli Fröhling has commissioned
a number of plants in recent years that
have achieved an excellent finished quality by
means of an improved cutter design (including
the new thin-strip plant at MKM in Hettstedt
for light-gauge copper strip up to 1,260 mm
wide, the slitters at PingAn or Nanshan in
China for aluminium strip up to 2,150 mm
wide or the high-performance slitter for
Ma’aden in Saudi Arabia).
Braking and coiling of the slit strip
The use of a looping pit to compensate for different
strip lengths after cutting (as a result of
the rolling profiles) has become standard practice
for slitters with a relatively large number
of strips with thickness in excess of 0.05 mm
(Fig. 4). This is the only way that one can
meaningfully achieve tension in the individual
strips that is as uniform as possible and
40 ALUMINIUM · 11/2013

SPe CIAL
effizienz zu steigern als auch die Bremswirkung
zu optimieren. Auch hier wird die
momentane Bandgeschwindigkeit als Messwert
benötigt. Erst jüngst hat die „Cutting
Edge Technology“ den chinesischen Kunden
Nanshan Aluminium dazu veranlasst, erneut
eine Längsteilanlage bei Fröhling zu beauftragen.
Ein gutes Beispiel ist die Längsteilanlage
inklusive Verpackungslinie, die vor einigen
Jahren bei Alcoa Europe Köfem in Ungarn
in Betrieb ging. Die Konzeption der Anlage
basiert auf den neuesten Erkenntnissen über
das Längsteilen dünner und weicher Materialien
mit Kreismessern. Kaltgewalzte harte
und weiche Aluminiumbänder von 0,05 bis
0,4 mm Banddicke mit einer Einlaufbreite
von max. 1.700 mm können in bis zu 130
Streifen geschnitten und aufgewickelt werden.
Das besondere Augenmerk galt der Vermeidung
von Oberflächenbeschädigungen
und dem Erreichen möglichst großer Fertigcoil-Durchmesser.
Realisiert wurde dieses
Ziel durch den Einsatz von Vakuumrollen
in mehreren Bereichen der Anlage, und zwar
im Auslaufbereich der CNC-Längsteilscheat
the same time still have large finished ring
diameters without overstretching the individual
strips or coiling them too tightly or too
loosely.
It was standard practice some years ago to
brake the strip (in other words apply a defined
tension) using strip presses, brake rolls or socalled
‘belt bridles’. All of these systems have
the disadvantage that there is strong contact
and friction between the braking medium
and the material. This can result in damage
NON-CONTACT
MEASUREMENT WITH
MORE PRECISION
MORE PRECISION
STRIP THICKNESS
& PROFILE
laser-optical measurement
with thicknessCONTROL
Fig. 5: Coiling of slit strip
Abb. 5: Aufhaspel für Spaltband
or contamination on the strip surface, which
can be troublesome or even lead to rejection,
especially with strip subjected to greater demands
(electronics industry, decoration, strip
for lighting applications, etc.).
Danieli Fröhling introduced its vacuum
technology for brake roll systems as long ago
as the 1990s and has continually upgraded
it ever since. With this technology, a partial
vacuum is used to produce a defined amount
of static friction that enables the coiler to have
the necessary strip tension. The same braking
force is applied to each individual strip, but
only on its underside, by purposely having
the roll run at a slower speed than the coiler.
The benefit is that there is considerably less
sliding friction compared with conventional
braking systems. The fact that the strip speed
is precise is beneficial for the process and
contributes to a further reduction in potential
sources of surface damage. There are now
more than 30 vacuum rolls in operation at
leading strip producers worldwide.
Fröhling’s latest developments are aimed
at optimising the suction performance of the
system in order to increase energy efficiency
as well as to optimise the braking efficiency. It
ALUMINIUM · 11/2013
bung verglichen mit konventionellen Bremssystemen.
Die Kenntnis der exakten Bandgeschwindigkeit
begünstigt den Vorgang und
trägt zu einer weiteren Reduzierung beschädigungsgefährdender
Oberflächeneinflüsse
bei. Inzwischen sind mehr als 30 Vakuumrollen
weltweit bei führenden Bandproduzenten
im Einsatz.
Neueste Weiterentwicklungen von Fröhling
zielten auf die Optimierung der Saugleistung
des Systems, um sowohl die Energie-
SPEED & LENGTH
optical sensor
with ASCOspeed
SPS/IPC/DRIVES / Nuremberg
26.11.2013 - 28.11.2013
Hall 7A / Stand 7A-138
www.micro-epsilon.com
MICRO-EPSILON | 94496 Ortenburg / Germany
Tel. +49 85 42/168-0 | info@micro-epsilon.com

ALUMINIUMwALzINDUSTRIe
© MicroEpsilon
ren, in der Mitte der Schlingengrube und
vor der Aufhaspel. Durch die Anordnung in
der Mitte der Schlingengrube wird eine Doppelschlinge
gebildet, wodurch sich die Kapazität
der Schlingengrube verdoppelt, ohne dass
das Band dabei beschädigt wird.
Die Anlage bei Alcoa zeichnet sich durch
weitere grundlegende Merkmale aus:
• Einsatz von CNC-Längsteilscheren, die
eine präzise Justierung der Messer-
Eintauchtiefe mit einer Genauigkeit von
± 2 μm ermöglichen
• Automatisches Wechselprogramm für
den CNC-Scherenblock
• Anlagenbetriebsgeschwindigkeit von
500 m/min im Schlingenbetrieb und
800 m/min im Durchzugsbetrieb
• Automatisches Zerkleinern der zu
dicken Bandenden mittels einer Trommelschere
mit einer Schneidgeschwindigkeit
von bis zu 200 m/min
• Hydraulisches Spannen des Aufhaspeldorns,
um den schnellstmöglichen Wechsel
von Haspelwellen mit verschiedenen
Durchmessern zu gewährleisten und
somit hohe Produktivität zu erzielen.
Steuerungstechnik und Sensorik
Abb. 6: ASCOspeed als Geschwindigkeitsmaster
Fig. 6: ASCOspeed as speed master
Neben den mechanischen Ausrüstungen, ist
Danieli Fröhling auch für die Elektrik und
Automatisierung verantwortlich. Dabei werden
außer der eigentlichen Antriebstechnik
auch die Level 1- und Level 2-Systeme geliefert.
Die Steuer- und Regelfunktionen des
Level 2 werden unter anderem für Online-
Monitoring sowie Maschinen- und Prozessüberwachung
genutzt, um die Produktionsleistung
und Produktqualität der Anlage zu
sichern. Eine große Anzahl von Parametersätzen
für die Setups unterschiedlicher Applikationen
hinsichtlich Material- und Legierungskenndaten,
Banddicke und Geschwindigkeitsvorgaben
liefert dem Bediener ein
hohes Maß an Komfort und das unabhängig
von der jeweiligen Bediencrew.
Einige Systemfunktionen seien hier beispielgebend
benannt:
• Setup-Berechnung und Aktualisierung für
alle Hauptanlagenteile
• Bandverfolgung
• Bandspannungs-/Bandzug-Überwachung
• Automatische Abbrems- und Anhaltesteuerung
sowie Durchmesserkontrolle
• Temperaturkompensation des Scherenmesser-Setups.
Die technologischen Schwerpunktgruppen
Schneiden mit Kreismessern, Bremsen und
Wickeln erfordern für ein optimales Zusammenspiel
eine leistungsfähige Echtzeiterfassung
des jeweiligen Betriebszustandes. Hier
setzt Fröhling auf die Zusammenarbeit mit
dem namhaften Sensorhersteller Micro-Epsilon,
der ein breites Portfolio von der Abstands-,
Dickenmessung bis hin zur Temperaturmessung
im Programm hat.
Wichtigste Messgrößen in einer Bandanlage
sind die hochpräzise Geschwindigkeitserfassung,
die Coilpositions- und -durchmessererfassung
sowie eine optionale Dickenmessung
des Bandes.
Die eingriffsfreie Geschwindigkeitsmesstechnik
ist für Danieli Fröhling eine seit langem
bewährte Technik. Lasermessgeräte an
Kaltwalzgerüsten und Weißlichtgeschwindigkeitsmessgeräte
an den Schneidlinien werden
von Fröhling seit vielen Jahren eingesetzt.
Während die Laser mit der Gefahrenklasse
3B besondere Betriebs- und Arbeitsschutzvorkehrungen
benötigen, ist die Weißlichttechnik
vollkommen ungefährlich. Beide Techniken
haben den Nachteil, dass spiegelnde Oberflächen
und Reflexionsänderungen bei unruhigem
Bandlauf zu Problemen führen können.
Die Weißlicht-Halogenquelle ist viel zu
träge, um hier in der Intensität angepasst zu
werden. Der Sensor wird durch sein eigenes
Licht geblendet und kann somit kurzzeitig
nicht messen. Auch beim Laser ist diese Problematik
bekannt. Ursache dafür ist der fein
gebündelte Laserstrahl, der auf glänzenden
Oberflächen leicht wegreflektiert wird.
Eine Lösung bietet hier das technische
Konzept des ASCOspeed-Geschwindigkeitssensors
von Micro-Epsilon. Beleuchtungsseitig
verbindet es die Vorteile Langlebigkeit
und Präzision der Laser mit der Robustheit
und Einfachheit eines Weißlichtgerätes und
ist doch technologisch etwas Neues. Eine
Hochleistungs-LED als Lichtquelle ist für die
is also necessary to measure the instantaneous
strip speed here. This ‘cutting edge technology’
recently led a Chinese client, Nanshan
Aluminium, to again place an order for a new
slitter with Fröhling.
Another good example is the slitter and
packaging line that was commissioned at Alcoa
Europe Köfem in Hungary a few years
ago. The plant concept is based on the latest
knowledge on the slitting of thin and soft materials
using circular knives. Cold-rolled hard
and soft aluminium strip with a thickness of
0.05 to 0.4 mm and a maximum inlet width
of 1,700 mm can be cut into up to 130 strips
and coiled.
Particular attention was given to avoiding
surface damage and obtaining as large a
finished coil diameter as possible. This was
achieved by using vacuum rolls at several
points in the line, namely in the lead-out area
of the CNC slitters, in the middle of the slackloop
pit and upstream of the coiler. The arrangement
in the middle of the slack-loop pit
forms two loops, which doubles the capacity
of the pit without damaging the strip.
The Alcoa plant is characterised by several
other basic features:
• the use of CNC slitters that permit precise
adjustment of the knife penetration
immersion depth to an accuracy of ± 2 μm
• a program for replacing the CNC cutter
block automatically
• a plant operating speed of 500 m/min in
the slack-loop mode and 800 m/min in the
full-tension mode
• automatic shredding of excessively thick
strip ends using a drum shear with a
cutting speed of up to 200 m/min
• hydraulic tightening of the reel mandrel in
order to ensure the fastest possible change
of reel shafts with different diameters, and
thus achieve a high level of productivity.
Control and sensor technology
In addition to the mechanical equipment,
Danieli Fröhling is also responsible for the
plant electrics and automation. Besides the
actual drive technology, it also supplies the
Level 1 and Level 2 systems. The control and
regulation functions of the Level 2 system are
used, amongst other things, for online monitoring
as well as for plant and process control
in order to ensure the output and product
quality of the plant. There are a large number
of sets of parameters for setting up various
applications with respect to material and alloy
characteristics, strip thickness and speed
settings and these offer the operator a high
degree of comfort, and do so independently
42 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM ROLLING INDUSTRY
of the respective operating crew. By way of
example one can mention some system functions
here:
• calculating the set-up and updating for all
main plant parts
• strip tracking
• monitoring of strip tautness / strip tension
• automatic control of braking and stopping
as well as monitoring of the diameter
• temperature compensation for the cutter
set-up.
As a technological entity, cutting with circular
knives together with braking and coiling
requires a powerful system for determining
the respective operating conditions in real
time in order to achieve an optimal interplay.
Here, Fröhling relies on co-operation with
Micro-Epsilon, the well-known manufacturer
of sensors, whose broad product portfolio
ranges from the measurement of displacement
or thickness through to temperature.
The most important measurements in a
strip line are highly accurate measurement of
the speed and determining the position and
diameter of the coil, as well as optional thickness
measurement on the strip.
The non-noncontact speed-measuring
technique that Danieli Fröhling has used for
a long time is well-proven. The company has
been using laser measuring devices on cold
rolling mills and white-light measuring devices
on the slitting lines for many years. The laser
is a safety class 3B device and requires special
operating measures and safety precautions,
but the white-light technology is completely
safe. Both technologies have the disadvantage
that reflecting surfaces and changes in the reflection
can cause problems if the strip is not
travelling smoothly. The halogen source of
the white light is then far too sluggish for the
intensity to be adapted. The sensor is dazzled
by its own light and can thus not carry out any
measurements for a short time. This is also a
familiar problem with lasers. The reason is
that the finely focussed laser beam reflects
off shiny surfaces slightly.
The ASCOspeed concept from Micro-Epsilon
offers a solution here. It combines the
benefits of the laser as a light source because
of its durability and precision with the robustness
and simplicity of a white-light device, but
technologically it is nevertheless something
new. A high-performance LED light source
is responsible for the outstanding properties
in use. The light has a narrow-band characteristic,
but the wavelength is not important
here. On the contrary, whereas much effort
is needed to stabilise the wavelength when a
laser is used, because its consistency affects
the accuracy, with the ASCOspeed technology
hervorragenden Anwendereigenschaften
verantwortlich. Das Licht besitzt zwar eine
schmalbandige Charakteristik, aber die Wellenlänge
ist hier ohne Funktion. Im Gegenteil,
während beim Laser die Laserwellenlänge
aufwendig stabilisiert werden muss, weil
deren Konstanz die Genauigkeit beeinflusst,
ist bei der ASCOspeed-Technologie die Referenz
durch die Struktur des Siliziumempfängers
gegeben. Dadurch wird eine hohe Präzision
und Langzeitstabilität sichergestellt.
Durch seine berührungsfreie Arbeitsweise
und leistungsfähige Interfacemöglichkeit
findet das ASCOspeed bevorzugt Einsatz
als Geschwindigkeitsmaster in Bandanlagen
(Abb. 6). Aus einer Distanz von 300 mm
misst das Gerät eingriffsfrei und ist damit
nicht zu nahe am Band. Berührungsfrei
heißt auch trägheitslos – damit ist schon
der Vorteil gegenüber einer inkrementalen
mechanischen Messung über Umlenkrollen
angesprochen, die je nach Masse oder Umschlingung
immer schlupft.
In den Spaltanlagen (Abb. 1) hat das
ASCOspeed 5500 für die Messerwellenregelung
und die Bundrechnersteuerung den
Drehimpulsgeber an der Umlenkrolle ersetzt
(Abb. 5) und liefert trotz Bandgeschwindigkeitsschwankungen,
verschiedener
Oberflächengüten
bis hin zu spiegelnden
Oberflächen
genaue und stabile
Messwerte bei den
unterschiedlichsten Scope of Products
Banddicken.
Die exakte Drehgeschwindigkeit
Continuous Roll Caster
der Messerwelle
ist verantwortlich
für hohe Schnittkantenqualität
und
Messerstandzeiten.
Cold Rolling Mill
Eine präzise und
direkte Messung
der Bandgeschwindigkeit
ist dafür die
Foil Mill
Vorraussetzung.
Eine interessante
Lösung ist der
Betrieb von zwei
Tension Leveller
Geräten für eine
Schlingengrubenregelung.
Aus der
Differenz zwischen
Pit Slitter
einlaufender und
auslaufender Bandlänge
ergibt sich die
aktuelle Länge der
SHANGHAI JIERU
jieru@sh-jieru.com
Schlaufe in der Grube (Abb. 4). Diese Art
der Messung ist oft gegenüber der direkten
Schleifenmessung mittels Laserabstandssensoren
im Vorteil, weil durch Schwingungen
der Bandschlaufe die Laserabstandsmessungen
schnell zum Problem werden. Das
Verarbeiten von weichen Bändern ist besonders
anspruchsvoll, da die Bänder möglichst
mit wenig Zug aufgewickelt werden sollten,
was durch entsprechende Bremsgerüste realisiert
wird. Das ASCOspeed liefert hierfür die
exakte Bandgeschwindigkeit.
In Besäumlinien bietet die Kenntnis der
exakten Bandgeschwindigkeit die Gewähr,
den Saumschnitt zu optimieren und den
Saumschrott problemlos abzuführen. Damit
trägt die Messtechnik (Abb. 7) entscheidend
dazu bei, die Anlagen bei den hohen Arbeitsgeschwindigkeiten
von bis zu 1.800 m/min
stabil zu fahren und gleichzeitig die hohen
Anforderungen an Schnitt- und Wickelqualität
zu erfüllen.
Für den An- oder Abtransport der Coils
werden neuerdings verstärkt Laserlaufzeitsensoren
eingesetzt, die die Coilposition millimetergenau
erfassen oder den Coildurchmesser
direkt vermessen können. Hier hat sich der
ILR1182 von Micro-Epsilon bewährt. ➝
Best solution supplier of
aluminium coil, sheet and foil manufacturing!
Turn-key Project Supplier
Hot Rolling Mill
Continuous Roll Caster
Cold Rolling Mill
Foil Rolling Mill
Tension Leveller
Cut-to-Length Line
Pit Slitter & Slitter
Foil separator
Foil Doubler Machine
Edge Trimmer and Rewind Machine
Color Coating Line
Caster Rolls and Shells
Chocks,Backup Rolls etc
Web: www.sh-jieru.com
ALUMINIUM · 11/2013 43

ALUMINIUMwALzINDUSTRIe
the reference is provided by the structure of
the silicon receiver. This ensures a high degree
of precision and long-term stability.
Thanks to the fact that it operates without
any contact and provides an opportunity to
have a powerful interface, the ASCOspeed is
used preferentially as the speed master in strip
plants (Fig. 6). The device carries out measurements
non-contact from a distance of
300 mm and is thus not too close to the strip.
Non-contact also means inertia-free – and this
already indicates the benefit over an incremental
mechanical measurement via deflection
rolls, which always results in slip depending
on the mass or the wrap-around.
In slitters (Fig. 1), the ASCOspeed 5500
has replaced the rotary encoder on the deflection
roll for regulating the knife shaft and
controlling the coil computer (Fig. 5) and provides
exact and steady measurements for the
widest possible range of strip thicknesses despite
fluctuations in the strip speed and different
surface finishes, even reflective surfaces.
The exact rotating speed of the knife shaft
is responsible for the high quality of the cut
edge and the long service lives of the knives.
Measuring the strip speed precisely and directly
is a prerequisite for this.
An interesting solution is the operation of
two units as a slack-loop pit for control purposes.
The actual length of the loop in the pit
is the difference between the lengths of strip
that have entered or exited the pit (Fig. 4).
This method of measurement is often benzusammenfassung
Gewichtsverringerung und Miniaturisierung
führen unweigerlich zu einem erhöhten Bedarf
an dünneren Bändern. Gleichzeitig führt
die Tendenz zu großen Bundgewichten und
geringeren Banddicken zu erhöhten Laufzeiten
auf den Anlagen.
Danieli Fröhling stellt sich diesen Marktanforderungen
mit der Entwicklung und Fertigung
von Hochgeschwindigkeitsschneidanlagen.
Das erfordert jedoch eine Optimierung
der Kreismesserscheren, deren konstruktiver
Aufbau, die Steifigkeit des gesamten Messerwellensystems
sowie die FEM-Analyse bis
hin zur Schnittspaltwahl und Eintauchtiefe die
Qualität des Schneidprozesses bestimmen.
Die Entwicklung von CNC-gesteuerten
Längsteil- und Besäumscheren ist eine der
wichtigsten Innovationen in der 65-jährigen
Tradition des Unternehmens.
Doch nicht nur der Schnitt bestimmt die
Qualität des fertigen Coils, sondern auch ein
exaktes Wickelbild gehört zu den Kundenforderungen.
Hier hat Fröhling mit der Vakuumtechnologie
als Bremsgerüst einen Meilenstein
gesetzt und kann bereits auf den Einsatz
von über 30 Vakuumrollen weltweit bei führenden
Bandproduzenten verweisen.
Die technologischen Schwerpunktgruppen
Schneiden mit Kreismessern, Bremsen und
Wickeln erfordern für ein optimales Zusammenspiel
eine leistungsfähige Echtzeiterfassung
des jeweiligen Betriebszustandes. Dazu
gehört eine hochpräzise Geschwindigkeitserfassung
sowie optionale Dickenmessung des
Bandes.
Durch seine berührungsfreie Arbeitsweise
und leistungsfähige Interfacemöglichkeit findet
das ASCOspeed bevorzugt Einsatz als
Geschwindigkeitsmaster in Bandanlagen, liefert
die Information für die Synchronisation
der Messerwelle sowie über die momentane
Bandlänge und kann des weiteren zur Schlingengrubenregelung
eingesetzt werden.
Durch ihre Qualität und Leistungsfähigkeit
erfreuen sich Schneidanlagen von Danieli
Fröhling, auch dank der genutzten, hochpräzisen
Messtechnik von Micro-Epsilon, weltweit
großer Beliebtheit.
Autoren
Dipl.-Ing. Detlef Neumann ist Vize-Präsident und
Vertriebsleiter der Josef Fröhling GmbH & Co. KG,
ein Unternehmen der Danieli-Gruppe.
Dr. Klaus Christofori ist als Produktmanager innerhalb
der Micro-Epsilon-Gruppe für die Geschwindigkeitsmesstechnik
verantwortlich.
Abb. 7: ASCOspeed-Installation an Hochgeschwindigkeitsbesäumschere Nanshan
Fig. 7: ASCOspeed installation at the Nanshan 3 high-speed trimming shear
eficial compared with direct measurement of
the loop using laser distance sensors because
oscillations in the strip loop can quickly create
a problem with the laser distance measurements.
The processing of soft strip is particularly
demanding because the strip has to be
coiled using as little tension as possible; this
is achieved using appropriate braking stands.
The ASCOspeed provides an exact measure
of the strip speed.
With edge-trimming lines, exact strip speed
allows the trimming to be optimised and ensures
the scrap produced can be removed
without difficulty. Here, the measurement
technology (Fig. 7) plays a key role in ensuring
that the lines operate smoothly at high working
speeds up to 1,800 m/min and at the same
time satisfy the high quality demands with respect
to cutting and coiling.
Recently, laser transit-time sensors have
been used increasingly for delivering and
removing the coils; these determine the position
of the coil with millimetre precision or
can measure the coil diameter directly. The
ILR1182 from Micro-Epsilon has proven its
worth here.
Summary
Weight reduction and miniaturisation are inevitably
leading to greater demand for thin
strip. At the same time, the trend towards
heavier coils and thinner strip is leading to
increased strip-processing times.
44 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM ROLLING INDUSTRY
Danieli Fröhling is satisfying these market requirements
by developing and manufacturing
high-speed slitting lines. However, this necessitates
optimisation of the circular knives,
their structural design and the rigidity of the
whole knife shaft system, including finite element
analysis, as well as the choice of cutting
gap and depth of penetration, which determine
the quality of the cutting process.
The development of CNC-controlled slitters
and trimming shears is one of the most
important innovations in the company’s 65-
year history.
However, it is not only the cut that determines
the quality of the finished coils: exact
winding is also part of the customer’s requirements.
By using its vacuum technology as the
braking stand, Fröhling has set new standards
and can point to over 30 vacuum rolls that
are already in use at leading strip producers
worldwide.
As a technological entity, cutting with circular
knives together with braking and coiling
requires a powerful measuring system
for determining the instantaneous operating
state in real time if an optimal interplay is
to be achieved. This includes highly accurate
measurement of the speed as well as optional
measurement of the strip thickness.
Thanks to its non-contact mode of operation
and the fact that it provides an opportunity
to have a powerful interface, the ASCOspeed
is used preferentially as the speed master in
strip plants, supplies the information for synchronisation
of the knife shafts and on the
instantaneous strip length, and can also used
with a slack-loop pit for control purposes.
Cutting machines from Danieli Fröhling
are very popular worldwide thanks not only
to their quality and performance but also to
the high-precision measurement technology
from Micro-Epsilon that is used.
Authors
Dipl.-Ing. Detlef Neumann is vice president and
sales manager at Josef Fröhling GmbH & Co. KG,
which is part of the Danieli group.
Dr. Klaus Christofori is product manager responsible
for speed measurement technology within the
Micro-Epsilon group.
3 rd Global Aluminium Foil Roller Conference on the horizon
The European Aluminium Foil Association
(EAFA), the global network leader of foil
producers, is organising the third Global Aluminium
Foil Roller Conference (Glafco), which
will be taking place from 15-17 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 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 a multilingual website www.
global-alufoil.org. The report demonstrates
alufoil’s versatility, through the multiplicity of
applications for which it is suitable. In addition
it shows the methods the industry is using to
provide solutions for a world facing growing
population, urbanisation, climate change, and
depletion of scarce resources.
The conference is open for foil rollers
worldwide. The programme includes the following
presentations:
• Global Economic Outlook
• Africa – the Hidden Growth Potential
• Outlook on the Global Primary Aluminium
Industry
• Global Foil Stock Market
• Strengthening Foils’ Competitiveness:
Contributions from the Suppliers’ Side
• Global Foil Markets – Trends, Challenges
and Opportunities
• Foil around the Globe: Country reports on
China, Europe, the Americas, Japan, South
Korea, India and other Asian and Middle
East Countries, Russia/Armenia, South
Africa
• Customer Perspective
• The Place of Foil within the Packaging
Material Portfolio of a Brand Owner
• The Future of Foil in Global Flexible
Packaging Markets
• The Conquest of the Global Wine Market –
the Success Story of Aluminium Closures
• Application and Prospects of Aluminium
Foil Containers in China
• High-tech Aluminium Foils in Li-Ion-
Batteries for Transporation and Energy
Storage
• Sustainability – the Aluminium Story
• Foil Recycling and Recovery Options
• Aluminium Recovery for Laminated Foil
Packaging
• Driving Value in Beverage Carton Recycling
• The Aluminium Stewardship Initiative: a
Responsible Path for the Development of
Foil Markets
• Global Foil Roller Network’s Future
Stefan Glimm: “The industry wants to continue
building one global voice for foil on sustainable
and promotion issues to support further
growth.”
• Resource Efficiency – Foils’ Key Branding
Opportunities and Activities of the Glafco
Network since 2011
• The Future of the Glafco Network: Ideas,
Discussion and Conclusions
• Conclusions from the Supplier View
The conference is accompanied by an social
programme including an afternoon exploration
of the desert with 4WDS followed by a
sunset dinner at a Bedouin desert camp . For
details see www.global-alufoil.org where you
can download the complete conference programme.
© Glimm
ALUMINIUM · 11/2013 45

ALUMINIUM ROLLING INDUSTRY
Alro commissions new cold finishing lines supplied by Salico
Aluminium producer and manufacturer
Alro SA has started operation of its
newly built cold finishing facilities at its
rolling plant in Slatina, Romania. The
€10 million (RON43.6m) investment is
aimed at increasing the mill’s productivity
and thus strengthening its international
competitiveness. The project, which was
started in March 2011, comprises tension
levelling, cut-to-length and slitting
lines. The company is majority owned by
the globally integrated aluminium group
Vimetco.
The new finishing facilities in Slatina include
state-of-the-art tension levelling, cut-to-length
and slitting lines, all of them supplied by Salico.
The lines process aluminium strip, mainly
5xxx alloys, in widths up to 1,650 mm and
a thickness range from 0.3 to 6.35 mm. The
new equipment has been in operation since
mid-September and has met all performance
and capacity requirements. With the new lines,
Alro will be able to offer a wide range of strip
thicknesses between 0.3 and 300 mm covering
all products from sheet, coil, slits, shapes
and plate. It has a production capacity of
120,000 tpy of finished products.
Tension levelling line
The centrepiece of the new equipment, the
tension leveller unit, features an ‘all electric’
drive system for the tension bridles with a
non-contact laser speed measurement system
and a heavy-duty cassette leveller as the main
components.
Eccentric rotary shear – ‘sheet tronic’
Tension levelling section
An intelligent arrangement of the cluster of
rolls of each cassette minimises friction for
the thinnest materials. At the same time, it
offers adequate stiffness to process heavier
thicknesses of hard alloys, and together with
an automatic disconnection system for the bridle
rolls this allows a very large range of strip
thicknesses to be processed.
The line is equipped with an automatic
spool handling system, edge trimming section,
double-die Salico stitching machine and
an inspection stand.
Particular effort has been devoted to the
design of the roll-cleaning systems, with motorised
cleaning devices for the entry and exit
deflector rolls and all the bridle rolls, as well
as an advanced lubricant spraying device for
the elongation and levelling sections of the
leveller.
Cut-to-length line
The cut-to-length line cuts the entry coils into
sheet up to six metres in length at a maximum
speed of 80 m/min. The main components are
a multiroller leveller, paper and plastic application
devices, an eccentric rotary shear and
a vacuum stacker. The leveller ensures that
the cut sheets have the proper flatness, with a
maximum of half the tolerance permitted by
the relevant European standard.
Preparation of the interleaving paper is carried
out easily and ergonomically by the operators
offline. Feeding the paper into the line
and under the aluminium strip is accomplished
fully automatically without intervention of the
operator.
The eccentric rotary shear is the patented
Salico ‘sheet-tronic’ shear, which has been
sold worldwide more than 200 times. A highly
dynamic and well balanced unit allows the
sheet to be cut with a high degree of accuracy:
the tolerance is less than 0.2 mm at the highest
speed with up to 160 cuts per minute. The
shear also features a camber-compensation
system that permits angular adjustment of the
complete unit in order to cut within the tolerance
even when the strip has a severe camber
defect on entry.
Stacking is accomplished using a zero-inertia
vacuum stacker based on a concept introduced
by Salico many years ago. It is performed
when the sheets are not moving: the
stacker belts are stopped at the very moment
when the stacking position has been reached.
This approach allows the cut sheets to fall vertically
onto the packing without any risk of
slippage, and therefore without any surface
damage even with the softest and most sensi-
© Salico
46 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM ROLLING INDUSTRY
Entry section of the slitting line
tive materials at maximum line speeds.
The plant layout has been designed in such
a way that the cut-to-length line and the tension-levelling
line can be operated together or
as stand-alone units.
mainly by the wrap force over the strips
around the electrically braked bridle rolls; this
avoids scratches and other surface damage.
Special attention was given to minimising
line downtime: specific solutions have been
provided for fast unloading of the spools, providing
slitter heads capable of performing test
cuts offline, changing the heads automatically
and offline strapping capabilities over the exit
turnstile.
■
Slitting line
The main equipment of the slitting line has to
perform the cutting and back-tensioning. Slitting
is carried out using two interchangeable
slitter heads equipped with the proprietary
Salico high-pressure tooling-locking system,
which continuously applies an axial pressure
of up to 25 MPa (250 bar) in order to ensure
that there are absolutely no gaps between the
knives and the spacers. Coupled with the fact
that the strip is under tension because of the
pulling rolls located after the slitter head, this
ensures optimal cutting quality. It is possible
to apply lubrication continuously to avoid
pick up of aluminium particles on top of the
knives.
The proprietary Salico tensioning bridle
even provides back-tensioning of the slit cuts
before recoiling. In contrast to the vertical
tension rolls or felt pad systems traditionally
used, tension is applied progressively here,
Gheorghe Dobra, CEO of Vimetco, and Jose M. Gerboles, CEO of Salico Group, celebrating the successful
completion of the Alro project with project team members
ALUMINIUM · 11/2013 47

ALUMINIUMwALzINDUSTRIe
Neue Schneidpräzision für Karosseriebleche aus Aluminium
© Schuler
Durch eine neuartige Laserschneidanlage
in Dormagen bietet der Aluminiumkonzern
Hydro seinen Kunden in der Automobilindustrie
künftig Karosseriebleche
in bislang nicht gekannter Präzision –
ein weiterer Fortschritt im wachsenden
Markt für den Fahrzeugleichtbau.
Eingeweiht wurde die Anlage von Hydro gemeinsam
mit ihrem lokalen Partner Alu-Laser-
Service GmbH & Co. KG (ALS) sowie dem
Lieferanten Schuler. Bei einer Jahreskapazität
von bis zu 20.000 Tonnen verstärkt sie den
Hydro-Standort Dormagen zu einem hochmodernen
Schneidezentrum nach Maß für Bandund
Blechanwendungen im Automobil – vor
allem für die Fahrzeugaußenhaut.
„Mit praktisch gratfreien Konturblechen,
von Lasern im kontinuierlichen Prozess direkt
aus dem Coil gestaltet, verarbeiten wir
unser Material sauberer und reduzieren Prozessschrott“,
erklärt Pascal Wagner, Leiter
Lithographie, Automotive & Wärmetauscher
bei Hydro. „Zugleich entstehen in der hoch
automatisierten Schneidanlage mit Festkörperlasern
hoch präzise Automobilbleche für
große und kleine Serien. So bedienen wir effizient
eine wachsende Vielfalt an Modellreihen
und kommen der Plattformstrategie führender
Fahrzeughersteller entgegen.“
Die Anlage schneidet per Laserstrahl Bänder
von 0,7 bis 3 mm Dicke in Platinen von
200 x 200 mm bis zu Maßen von 2.000 x
4.000 mm. Das ermöglicht Elemente vom
Kleinteil zur Karosserieverstärkung über die
Motorhaube bis zur kompletten Seitenwand
eines Premium-Fahrzeugs.
Das Vormaterial kommt aus dem nahe
gelegenen Hydro-Walzwerk Grevenbroich.
Dessen Glühlinie im Zentrum für Automobilbänder
wird zurzeit auf eine Kapazität bis zu
50.000 Jahrestonnen fast verdoppelt – vor
Bei Laseranlagen mit DynamicFlow-
Technologie, wie jetzt erstmals in Dormagen
installiert, entfallen Investitionen
in Werkzeuge und deren Instandhaltung
sowie Werkzeugwechsel in der Produktion vollständig
Laser lines with DynamicFlow Technology mean that no
investment is needed for buying and maintaining dies
and no production time is lost changing them
dem Hintergrund, dass der europäische Markt
für Alukarosserien zwischen 2011 und 2018
schätzungsweise jedes Jahr um 15 bis 20 Prozent
wachsen wird.
In Dormagen hat der Maschinenbauer
Schuler erstmals seine neu entwickelte DynamicFlow-Laserschneidtechnologie
installiert.
Betrieben wird die Anlage auf dem Gelände
der Hydro von dem Unternehmen Alu-Laser-
Service (ALS). „Mit ALS-Geschäftsführer
Heinz-Walter Schewe setzen wir eine schon
bei der Längsteilanlage nebenan bewährte,
langjährige Zusammenarbeit fort“, so Franz
Steimmel, Leiter des Produktbereichs Automotive
und Wärmetauscher bei Hydro.
New edge in precision cutting of body sheet
Thanks to a novel laser-cutting facility
at the site in Dormagen, Germany, the
aluminium company Hydro can now offer
its automotive customers body sheet of
unmatched precision, taking yet another
step forward in the growing market for
automotive light-weighting with aluminium.
Eine weitere Partnerschaft
begann Hydro vor
kurzem auch mit dem
Konzern Kobe Steel in Japan:
Über den Austausch
von Technologie stärken
sich beide Unternehmen
gegenseitig als Anbieter
hochwertiger Aluminiumwalzprodukte
gegenüber
einem zunehmend globalisierten
Einkauf und einer
globalen Produktion in
der Automobilindustrie.
Hydro beliefert vor allem
die führenden Premiumhersteller
in Europa.
„Mit all diesen Entscheidungen
folgen wir
unserer Strategie, im Geschäft
mit Walzprodukten
unsere führende Stellung
durch innovative
Lösungen und Produkte zu festigen – und
helfen insbesondere der Automobilindustrie,
mit nachhaltigen Lösungen den Leichtbau
von Fahrzeugen voranzubringen und deren
CO 2 -Ausstoß zu verringern”, erklärt Hydro-
Konzernvorstand Oliver Bell, der für das
Geschäft mit Walzprodukten verantwortlich
ist.
■
The new facility was inaugurated by Hydro
together with the local operator Alu-Laser-
Service and its supplier Schuler. Adding a capacity
of up to 20,000 tonnes a year, the new
facility boosts the Hydro site at Dormagen into
a most modern cut-to-size centre for automotive
strip and sheet applications, in particular
for body-in-white parts.
“In a continuous process, our aluminium
sheets are being shaped directly from the coil
by solid state lasers that cut practically burrfree.
Thereby we make manufacturing cleaner
and reduce process scrap,” says Pascal Wagner,
head of Hydro’s Lithography, Automotive &
Heat Exchanger business unit. “Furthermore,
this highly automated laser-cutting facility delivers
high-precision car sheet both for large
and for small volume series. Thus we are able
to efficiently service a growing variety of
model series and accommodate the platform
strategy of leading carmakers.”
48 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM ROLLING INDUSTRY
Aus einem ständig laufenden Blechband
werden mit einem hochmodernen Laserverfahren
Platinen geschnitten
Cutting-edge lasers are used to form
blanks from a continuously running coil
On the new line, laser beams cut aluminium
strip of gauges between 0.7 and 3 mm
into sheets from 200 x 200 mm up to 2,000 x
4,000 mm. This enables the customer to form
elements from small parts to fortify the body
over one-piece bonnets onto complete side
panels for premium automobiles.
The stock comes from Hydro’s rolling
mill in nearby Grevenbroich, where capacity
of the annealing line in the centre for automotive
strip is being almost doubled, up to
50,000 tonnes a year – based on a European
market for aluminium car body that is expected
to grow by 15 to 20 percent each year
between 2011 and 2018.
In Dormagen, the engineering company
Schuler has installed the very first type of
its newly developed DynamicFlow laser-cutting
technology. On Hydro’s Dormagen site,
the new facility is operated by the Alu-Laser-
Service (ALS). “We thereby continue a partnership
with ALS managing director Heinz-
Walter Schewe that has proven successful already
for many years with the slitting facility
next door,” says Franz Steimmel, head of the
Automotive & Heat Exchanger product group
in Hydro.
Recently, Hydro also established a partnership
with the Kobe Steel group from Japan:
through exchange of technology, both parties
strengthen each other as suppliers of premium
rolled aluminium products for an increasingly
global sourcing and manufacturing in the automotive
industry. Hydro primarily supplies
to the leading premium carmakers in Europe.
“All these decisions follow our strategy
in the Rolled Products business to keep our
leading edge by offering innovative solutions
and advanced products – while helping namely
the automotive industry to boost the making
of light-weight cars and thereby reduce
automotive CO 2 emissions,” says Hydro executive
vice president Oliver Bell, who leads
Rolled Products.
■
Installation of UACJ cold-rolling mill for Thailand in final stage
In recent years, the demand for aluminium
has increased worldwide, especially in the automotive
industry. This has led Japanese manufacturers
to expand overseas, as they seek to
provide high-quality aluminium products for
the global market. The UACJ Group has also
been establishing production and sales bases
in regions around the world to strengthen its
network and ensure stable supply.
As part of this plan, the company is currently
constructing a new integrated factory in
Thailand that will undertake all processes related
to rolled sheet production, from melting
to casting, rolling and finishing. Initially, the
new factory will supply products such as can
end and automotive heat exchanger materials.
Work on the new factory began in March
2012. Construction and installation is now in
the final stage for the cold-rolling to finishing
line. Start of operations is scheduled for January
2014.
Construction on a second line has also been
underway since February 2013. This line, to be
commissioned in March 2015, aims at handling
casting and hot-rolling processes. The facility
is expected to have a total production
Advertisement
capacity of up to 180,000 tonnes a year. “This
volume will give us a clear edge in cost over
our competitors, including Chinese and Korean
manufacturers, who have grown in market
strength in recent years,” UACJ says. ■
ALUMINIUM · 11/2013 49

ALUMINIUMWALzINDUSTRIe
Energy Advisor von SMS Siemag
energieströme transparent machen und energieverbrauch senken
J. Mellenthin, SMS Siemag
Die Produktion von Hüttenaluminium
ist bekanntermaßen sehr energieintensiv.
Auch für die anschließende Verarbeitung
von Aluminium zu Halbzeugen durch
Walzen und Wärmebehandlung stellt der
Energieeinsatz einen entsprechend gro ßen
Kostenblock dar. Dies gilt nicht nur für
die Produktion in Deutschland mit seinen
hohen Energiepreisen. Auch in Regionen,
in denen Energie vergleichsweise günstig
ist, kommt der Reduzierung des Energieeinsatzes
aus Kosten- und Umweltgründen
zunehmende Bedeutung zu. Mit dem
„Energy Advisor“ hat SMS Siemag ein
Energiedaten-Managementtool entwickelt,
mit dem sich Energieströme im Produktionsprozess
verfolgen und optimieren
und damit Energiekosten senken lassen.
Preiserhöhungen aufgrund standortspezifischer
Sonderlasten sind in einer Branche,
die in einem intensiven globalen Wettbewerb
steht, kaum durchzusetzen. Umso wichtiger
ist es, alle Potenziale zu aktivieren, um international
wettbewerbsfähig zu bleiben. Ein
Energiedaten-Managementsystem wie der
Ener gy Advisor von SMS Siemag kann dabei
wichtige Impulse geben, indem er Energieströme
ganzheitlich betrachtet und beurteilt.
Ein Energiemanagementsystem nach ISO
50001 ermöglicht Transparenz über Energieflüsse
bzw. den Energieverbrauch im gesam -
ten Produktionsprozess. Dadurch ergeben
sich aussagekräftige Daten, deren Auswertung
hilft, Energiekosten und CO 2 -Emissionen zu
reduzieren. Erfahrungswerte zeigen: Mithilfe
eines Energiemonitoringsystems lassen sich
zweistellige Kosteneinsparungen erreichen.
Die Amortisierungszeit dieser Systeme liegt
häufig unter zwei Jahren.
SMS Siemag bietet mit seinem Energy Advisor
im Bereich der Hütten- und Walzwerkstechnik
ein entsprechendes Energiedaten-
Managementtool, das über das reine Monitoring
hinausgeht. Idealerweise findet es schon
beim Engineering neuer, energieeffizienter
Anlagen Berücksichtigung. Übergreifende
Kenntnisse der Elektrik und Automation sowie
der Prozesstechnologie ermöglichen eine
kostengünstige Integration, da schon beim
Bau der eigentlichen Anlage auf die ohnehin
zu installierenden Sensoren und Aktoren
zurückgegriffen werden kann. Schnittstellen
können so deutlich minimiert werden. Doch
The SMS Siemag Energy Advisor
Making energy flows transparent, cutting consumption
J. Mellenthin, SMS Siemag
It is well known that aluminium production
is very energy-intensive. Subsequent
processing into semi-finished products by
rolling and thermal treatment also takes
a lot of energy that is a correspondingly
high cost factor. This applies not only
to production in Germany with its high
energy prices. There are similar considerations
even in regions with relatively
cheap energy, where reducing consumption
is becoming ever more important
for reasons of economy and environment
protection. That is where the Energy Advisor,
a data management tool developed
by SMS Siemag, comes in handy because
it tracks and optimises energy flows in the
production process to help save costs.
Trying to raise prices due to specific local burdens
hardly seems a viable plan in an industry
that operates under intensive global competition.
Therefore it is all the more vital to utilise
every potential available for staying internationally
competitive. A management system
like the Energy Advisor from SMS Siemag can
help by providing vital pointers from the observation
and analysis of total energy flows.
Such an energy management system – fully
compliant with ISO 50001 – makes energy
flows and consumption transparent throughout
the production process. Further, it delivers
the data producers need to analyse energy
outgoings and reduce CO 2 emissions. Experience
has shown that cost savings in double
figures can be achieved with an energy monitoring
system. That’s why these solutions often
pay for themselves after less than two years.
What SMS Siemag offers with its Energy
Advisor for the metallurgical plant and rolling
technology segment is a tool that goes beyond
mere monitoring. Ideally, it even impacts on
the engineering process by identifying new,
energy-efficient plants at this early stage. Also
available is interdisciplinary expertise covering
electrics and automation as well as process
technology for low-cost integration. That is because
the sensors and actors to be installed in
the plant anyway can be included in the more
efficient design right from the start. This significantly
minimises the number of interfaces.
Yet the Energy Advisor can also be retrospectively
integrated into existing plants, whether
built by SMS Siemag or other suppliers.
A host of benefits for
the aluminium industry
Compared to the high energy input required
for primary aluminium production, the power
used by aluminium rolling mills incorporat -
ing hot and cold rolling mills, heating and thermal
treatment furnaces, as well as strip processing
lines appears fairly moderate. However,
developments in the energy-conscious
© SMS Siemag
50 ALUMINIUM · 11/2013

Novelis PAE Expert in
Casthouse Equipment
Using our technical expertise and experience,
we engineer, build and commission complete
CC and DC aluminium casting lines.
Continuous strip roll casters JUMBO 3C - 3CM
DC slab and billet casters, AUTOPAK automation system
In-furnace metal treatment system IRMA
In-line metal treatment units ALPUR , JETCLEANER , PDBF , CFF
After-sales services
novelis.com/PAE
Novelis PAE
Centr’Alp • BP 24
38341 Voreppe cedex
France
Tel +33 4 76 57 87 00
Fax +33 4 76 56 65 39
pae.marketing@novelis.com
www.novelis.com/PAE
Certified by Bureau
Veritas Certification
ISO 9001 • ISO 14001
OHSAS 18001

ALUMINIUMWALzINDUSTRIe
auch bei bestehenden Anlagen, seien es Eigenoder
Fremdanlagen, kann der Energy Advisor
nachträglich integriert werden.
Vielfältiger Nutzen für
die Aluminiumindustrie
Gemessen am hohen Energieeinsatz, der zur
Erzeugung von Primäraluminium in der Aluminiumhütte
erforderlich ist, erscheint der
Energiebedarf eines Aluminiumwalzwerkes
mit seinen Warm- und Kaltwalzwerken, den
Erwärmungs- und Wärmebehandlungsöfen
sowie den Bandbehandlungslinien bisher eher
Walzprozess im Vorgerüst
moderat. Die Entwicklungen im bewussten
Umgang mit Energie bei Anlagen, die in den
letzten Jahren errichtet wurden, haben jedoch
gezeigt, dass auch hier noch deutliche
Verbesserungspotenziale gegeben sind. Um
hier gezielt vorzugehen ist es wichtig, nicht
nur die primären Energieverbraucher wie die
Beheizung von Öfen oder Hauptantriebe von
Walzwerken zu betrachten. Der Einsatz des
Energy Advisors gibt auch wertvolle Aufschlüsse
über den nicht unerheblichen Verbrauch
von Nebenanlagen wie Hydraulikantriebe,
Absauganlagen und Druckluftversorgung.
Bleiben wir beim Walzwerk: Abgesehen
von der transparenten Darstellung der Energieverbräuche
der Hauptantriebe kann der
Energy Advisor eingesetzt werden, um dem
Bedien- und Wartungspersonal konkrete
Handlungsempfehlungen für eine energieoptimierte
Fahrweise der Nebenanlagen zu geben.
So werden zum Beispiel Handlungsempfehlungen
für Walzpausen gegeben, in denen
die gesamten Nebenanlagen – soweit prozesstechnologisch
vertretbar – heruntergefahren
werden können und erst kurz vor dem Wiederanwalzen
ihre volle Leistung erreichen.
Ähnlich verhält es sich beispielsweise bei
Bandbeschichtungslinien. Bei den von SMS
Siemag eingesetzten GATV-Trocknungsöfen
wird die Strategie verfolgt, die Gasreinigung
so auszulegen, dass die im Abgas enthaltenen
flüchtigen Lackbestandteile wieder dem Verbrennungsprozess
zugeführt werden. Dies
kann so weit gehen, dass die Anlage unter
bestimmten Voraussetzungen einen autothermen
Betriebszustand erreicht, der den Energieverbrauch
erheblich reduziert. Diese sehr
effiziente Maßnahme kann mit dem Energy
Advisor überwacht und optimiert werden,
sodass das Bedienungspersonal stets über
den Status des Prozesses informiert ist. Der
Energy Advisor spricht eine Empfehlung für
Rolling process in a roughing stand
die weitere Steuerung der Anlage aus. Diese
mit relativ geringem Investment verbundenen
Prozessoptimierungen münden in deutlichen
Energieeinsparungen.
Eine ähnliche Prozessüberwachung mit
dem Energy Advisor ist bei Glühlinien für
hochwertiges Aluminiumband möglich, in
denen SMS Siemag wie gegenwärtig bei der
Anlage für Ma’aden-Alcoa in Saudi Arabien
eine Luft-/Wasser-Kühlstrecke zum Erzielen
hoher Abkühlraten einsetzt.
Besonders sinnvoll kann der Energy Advisor
eingesetzt werden, um Überlegungen
in Verbindung mit geplanten Anlagenmodernisierungen
zu unterstützen. Entscheidungen
für eine Anlagenmodernisierung werden in
zunehmendem Maße nicht nur vom Erhaltungszustand
einer Anlage bestimmt, sondern
auch von deren Energieeffizienz. Eine Senkung
des Energieverbrauchs ist nicht nur unter
Umweltaspekten wünschenswert. Sie kann
vielmehr zu deutlichen Kostensenkungen
führen und damit den ROI der Modernisierungsmaßnahme
begünstigen.
Der Energy Advisor leistet hier wertvolle
Hilfe bei der Analyse der Verbrauchsdaten
und damit auch der Energieverlustquellen einer
bestehenden Anlage.
operation of plants erected in recent years
have revealed substantial potentials for savings
in this field as well. To gain maximum
benefit, it is essential to examine not only the
primary energy consumers such as furnace
heating or the main drives of rolling mills.
Going beyond this narrow focus, the Energy
Advisor also flags up the not inconsiderable
consumption of auxiliary plants such as hydraulic
drives, extractors and compressed air
supply.
But let us get back to the rolling mill. Apart
from transparent display of the energy consumption
of main drives, the Energy Advisor
can give operating and maintenance personnel
concrete instructions for energy-optimised
running of auxiliary plants. Included here for
instance are recommended rolling breaks
during which all auxiliary plants – as far as
possible without disrupting the process – are
powered down and only run up again shortly
before rolling resumes.
There are similar options available for strip
processing lines. Central to the special strategy
SMS Siemag applies in its GATV drying
furnaces is a gas cleaning system designed in
such a way that the volatile paint substances
in the exhaust gas are channelled back into
the combustion process. Potentially and under
certain conditions, the plant can even achieve
an autothermal operating condition that
slashes energy consumption. This is a highly
efficient process monitored and optimised by
the Energy Advisor so that the operating personnel
is always fully aware of its status. Furthermore,
the Energy Advisor recommends
the next steps for controlling the plant. Best
of all, it takes relatively low investment to implement
these process optimisations which, in
turn, produce significant energy savings.
Intralogistik-Lösungen
neu im Internet unter
www.herrmannhieber.de
Equally effective in process monitoring is
the Energy Advisor for premium aluminium
strip annealing lines. Currently, SMS Siemag
is installing the system at Ma’aden-Alcoa in
Saudi Arabia in an air / water cooling section
to achieve high cooling rates.
Where the Energy Advisor has proved especially
useful is in planning plant revamps.
Increasingly, decisions on modernisation projects
are not just based on the condition of
a plant, but also on its energy efficiency. Reducing
energy consumption is not only better
52 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM RoLLINg INDUSTRY
for the environment. More than that, it can
noticeably cut costs and improve the ROI of
the modernisation.
All this goes to show that the Energy Advisor
is a valuable tool for analysing consumption
data and therefore sources of energy loss
in existing plants.
energy information at a glance
The Energy Advisor is part of the ‘Ecoplants’
range. Under this label, SMS Siemag presents
sustainable solutions for saving raw materials,
operating materials and energy. Also included
in the programme are reducing emissions and
recycling scrap from manufacturing. If at least
one of these criteria is met, the corresponding
product is classed as an Ecoplants solution.
That applies to the Energy Advisor because it
helps save energy, contributing to a reduction
in greenhouse gases and other emissions.
The Energy Advisor assesses the individual
production conditions and can be adjusted to
the particular plant. Apart from electricity,
it also monitors other media such as fuels,
gases, compressed air, heat or water for comprehensive
energy management. The system
automatically cumulates the measured values
and shows the operator the plant’s energy efficiency
on displays in the form of dial gauges
or traffic lights. That makes the display easy
to read at a glance and provides an instant
picture of the energy situation.
Plant evaluations using efficiency indicators
allow comparisons with previous values
or other areas. It is equally possible to compare
and analyse different materials and types of
energy in the process. The system also compiles
reports on the consumption of either the
entire plant or individual parts. There is even
the option of showing costs broken down according
to where they are generated and assigning
consumption completely or partly to
cost centres. This is how the Energy Advisor
can be used to track consumption of the various
energy types.
“The absolute energy consumption data
is not enough to be able to analyse the energy
situation in an aluminium plant. You also
need key performance indicators and curves
in conjunction with the production conditions.
If you define positive and negative limit values
for key performance indicators, you can use
them to evaluate the ongoing production process,”
says Prof. Ingela Tietze of Niederrhein
University. Crucial here are, for instance, the
use of high-power energy and its effect within
the process.
To meet these requirements, the energy
data management system from SMS Siemag
energiesituation auf einen Blick
Der Energy Advisor ist Teil des „Ecoplants“-
Konzepts. Unter diesem Label arbeitet SMS
Siemag an nachhaltigen Lösungen zur Einsparung
bei Rohmaterial, Betriebsstoffen und
Energie und damit verbundenen Emissionsminderungen
inklusive des Recyclings von
Fabrikationsschrotten. Ist mindestens eines
dieser Kriterien erfüllt, wird das entsprechende
Produkt als Ecoplants-Lösung eingestuft.
Dies trifft auf den Energy Advisor zu,
der Prozessenergie einsparen hilft und damit
dazu beiträgt, Klimagas- und andere Emissionen
zu verringern.
Der Energy Advisor berücksichtigt die jeweiligen
Produktionsbedingungen und lässt
sich individuell auf die jeweilige Anlage anpassen.
Neben der elektrischen Energie erfasst
er auch weitere energierelevante Medien wie
Kraftstoffe, Gase, Druckluft, Wärme oder
Wasser, wodurch ein umfassendes Energiemanagement
möglich wird. Die Messwerte
werden automatisch zusammengefasst, und
die Energieeffizienz der Anlage wird dem
Bediener durch Bildschirmanzeigen in Form
von Tachometern oder Ampeln angezeigt.
Die Darstellung ist so sehr übersichtlich und
bietet einen schnellen Überblick über die
Energiesituation.
Die Bewertung der Anlagen mit Effizienzindikatoren
erlaubt den Vergleich mit
Werten aus Vorperioden oder anderen Bereichen.
Unterschiedliche Werkstoffe und
Energien lassen sich im Prozess vergleichen
und bewerten. Die Verbräuche der gesamten
Anlage oder auch nur einzelner Anlagenteile
werden berichtsmäßig zusammengefasst. Zur
verursachergerechten Kostenabrechnung
können Verbräuche ganz oder teilweise den
Kostenstellen zugeordnet werden. Somit lässt
sich auch das Controlling der Energieverbräuche
im Energy Advisor abwickeln.
„Um die Energiesituation in einem Aluminiumwerk
bewerten zu können, sind die
absoluten Energieverbrauchsdaten nicht ausreichend.
In Verbindung mit den Produktionsbedingungen
müssen zusätzlich Kennzahlen
und Kennlinien festgelegt werden. Für
Kennzahlen lassen sich positive und negative
Grenzwerte definieren, mit denen eine
Bewertung des momentanen Produktionsprozesses
erfolgt“, erklärt Prof. Ingela Tietze von
der Hochschule Niederrhein. Beispielsweise
ist der Einsatz von gehaltvoller Energie und
deren Wirkung im Prozess entscheidend.
Um diese Anforderungen zu erfüllen, werden
beim Energiedatenmanagement von SMS
Siemag auch die Produktart und deren Mengen
erfasst. Somit lassen sich Verbrauch und
Die Energie- und Mediendaten werden mit den Produktions- und Statusinformationen verknüpft und in
dem Energy Advisor ausgewertet / The energy and media data is linked with the production and status
information, then analysed in the Energy Advisor
Produktion in Relation setzen und mithilfe
von Kennzahlen darstellen. Diese aus verschiedenen
Messwerten berechneten Größen
erlauben Anlagen- oder Situationsvergleiche.
Können oder sollen Produktionsdaten oder
-bedingungen nicht quantitativ in Kennzahlen
eingerechnet werden, nutzt man Kennlinien.
Eine Kennlinie berücksichtigt, dass die Kennzahlen
unter bestimmten Umständen im Produktionsprozess
unterschiedliche Werte annehmen
können. Auf diese Weise kann zum
Beispiel bei hoher Auslastung ein geringerer
Energieverbrauch je Produkteinheit erzielt
werden als in Zeiten geringer Produktion.
Wird die Kennzahl gegen die Einflussgröße
aufgetragen, lassen sich gleichartige Umstände
vergleichen und die verschiedenen Anlagensituationen
sinnvoll auswerten.
Zudem entwickelt SMS Siemag derzeit
ein Prognose-Tool. Basierend auf den bereits
gespeicherten Energiedaten, den Produktionsdaten
sowie dem künftigen Produktionsplan
ALUMINIUM · 11/2013 53

ALUMINIUM RoLLINg INDUSTRY
können mittels „neuronaler Netze“ Modelle
gebildet werden, die selbstlernend die Energiedaten
interpretieren. Mit deren Hilfe lässt
sich der Energieverbrauch abbilden und für
die Zukunft vorhersagen. Eine verlässliche
Vorhersage des Energiebedarfs hilft den Energieversorgern,
auf Bedarfsschwankungen
zu reagieren und dies durch günstigere Tarife
zu honorieren. Alternativ können die gewonnenen
Informationen für eine individuelle
Beschaffungsstrategie genutzt und der Strom
direkt auf dem Energiemarkt eingekauft werden.
Autor
Dr. Jesper Mellenthin ist Projektmanager Energieeffizienz
im Geschäftsbereich Elektrik und Automation
bei SMS Siemag AG, Düsseldorf.
also logs the product type and the quantities
produced. That puts consumption and production
in relation to each other and supplies
key performance indicators. In turn, these indicators
calculated from different measured
values make it possible to compare plants or
situations.
If analysts do not want production data or
conditions shown quantitatively in key performance
indicators, they use curves instead.
A curve takes account of the fact that under
certain circumstances in the production process
the key performance indicators can have
different values. For example at high capacity
utilisation, lower energy consumption per
product unit can be achieved than during periods
of low production. Combining key performance
indicators with the variables means
similar conditions can be compared and the
various plant situations usefully evaluated.
Furthermore, SMS Siemag is currently developing
a prediction tool. Based on already
saved energy data, production data and the
future production plan, the tool uses ‘neuronal
networks’ and self-learning to generate
models that interpret the energy data. It can
be used to map and predict energy consumption.
A reliable prediction of energy demand
helps energy utilities react to fluctuations in
demand and offer cheaper tariffs. Alternatively,
the information gained can be used for an
individual sourcing strategy for direct purchasing
of electricity on the energy market.
Author
Dr. Jesper Mellenthin is project manager Energy
Efficiency in the Electrics and Automation division
of SMS Siemag AG in Düsseldorf, Germany.
Danieli Aluminium Technology Forum 2013
Latest breakthrough technology in industrial operation
B. Rieth, Meerbusch
This year’s Technology Forum by Danieli
was very much focused on the processing
of aluminium. In a two-day symposium
held at its headquarters in Buttrio
in northern Italy, around 150 invited
guests from the international aluminium
industry were presented with the company’s
latest developments in the sectors
of rolling and processing high-grade
aluminium strips and plates, extruding
profiles and roll-casting aluminium rod.
Other topics of the presentations were
plant automation and drive technology as
well as know-how support and servicing.
The successful event was rounded off by
a tour of Danieli’s workshops and – as a
particular highlight – a joint flight of the
participants to Belgium to see the cold
rolling mill supplied by Danieli Fröhling
for automobile strips to Aleris in Duffel.
The participants, from 73 companies
in 36 countries, were given interesting
insights during the event into Danieli’s
latest technologies for a broad segment of
the aluminium value chain.
© Danieli
Gianpietro Benedetti, chairman and CEO of
Danieli & C. …
In his welcoming address Danieli chairman
and CEO Gianpietro Benedetti laid stress on
the leading role his company has played for
many years in the development of the most
modern technologies for the metallurgical
industry, that is the production and processing
of steel and NF metals. The globally active
company founded by the brothers Danieli in
1914 has meanwhile become the nucleus of a
worldwide network of highly specialised companies
in the sector of plant and machinery
engineering, each with various core interests
and each a market leader in its own field. With
an annual turnover of some three billion euros
… and Franco Alzetta, COO of Danieli & C.
during their opening addresses
and more than 10,000 employees worldwide,
Danieli is today one of the largest plant engineering
groups in the metallurgical sector.
In past years the core products of the group
and hence also its main expertise and growth
performance were governed almost exclusively
by steel. However, the market downturns
seen by steel in the more recent past,
54 ALUMINIUM · 11/2013

The difference between ordinary and
extraordinary is that little bit extra!
Advanced Technologies and Equipment for
Cold Rolling and Cutting.
Providing that Little Bit Extra
Since 1947.
Cold Mills ♦ Foil Mills ♦ Slitting ♦ Trimming ♦ Cut to
Lentgh ♦ Electrostatic Oilers ♦ Fume Cleaning & Oil
REcovery Systems ♦ Revamping ♦ Services ♦ Spare
Parts
Josef Fröhling GmbH & Co KG
Scherl 12
58540 Meinerzhagen
Tel +49-2354-7082-0
Fax +49-2354-7082-200
contact@danieli-froehling.de

ALUMINIUM RoLLINg I NDUSTRY
combined with the impressive increase in the
industrial use of aluminium even in highly
specialised applications, as well as recourse
to the know-how available from some members
of the Danieli Group such as Fröhling
and Wean / United, strongly suggested that
the group’s interests should be extended to
products for the production and processing of
aluminium. With this in view, Danieli has extended
its activities to the aluminium industry
and there are already
several product
lines involved
in the design and
commissioning of
plants for flat and
long aluminium
products, in particular
those that deal
with hot and cold
rolling, extrusion,
stretching, scrap
recycling, heat
treatment, finishing
lines, automation
and services.
Seven of the
group’s companies,
the Processing Divisions,
with their
lengthy experience
of aluminium, now
form the Danieli
Aluminium Division.
They are supported by the so-termed
Complementary Services for implementing
objectives related to all aspects of the material.
Accordingly the Danieli Aluminium Division
is now able, besides highly specialised individual
machines, also to supply and commission
complete production and processing
plants for the aluminium industry.
Each of the product presentations demonstrated
clearly how fully the individual members
of the Aluminium Division feel committed
to the Danieli philosophy. Franco Alzetta,
Danieli’s COO, expressed this by coining the
term ‘innovaction’, a condensation of the concept
‘innovation in actions’. Another of Danieli’s
principles, aimed at ensuring high quality
and reliable, on-time delivery, is expressed
by saying: “We don’t shop around, we build
all equipment in our own worldwide workshops.”
Besides the parent workshop in Buttrio
with its approx. 3,000 employees, this
refers to the similar but even larger operation
in Thailand and also to other production facilities
in China, Germany, India and Russia.
ALUMINIUM will be devoting parts of
the coming issues to individual and detailed
accounts of particularly interesting themes of
the Forum. The comments below are intended
to offer our readers in the first instance a review
of the two-day event. Their content aims
at a high level, going well beyond the scope of
usual product presentations. In fact, Danieli’s
Aluminium Technology Forum 2013 reflected
the group’s own expertise in the context of
the current opportunities and threats faced by
the worldwide aluminium industry.
6-high Diamond Mill for 2,300 mm wide automotive body sheet at Aleris in Belgium
To begin with, the company offered an insight
into its assessment of the current global
aluminium market. “The latest needs of the
market”, stated Giorgio Ximeris, manager of
the Danieli Flat Product Division, “have demonstrated
that aluminium is a material that
covers an increasingly wide spectrum of applications,
from the ‘historical’ ones such as
cans or packaging for food and drugs, to the
most innovative ones for the aeronautical and
automotive industries.”
Against that background much interest was
shown in the subject of ‘Aluminium Sheet in
Automotive Applications’. Jaguar Land Rover
described the development of the aluminium
body structure strategy of the new Range
Rover. With 74% of the complete body structure
being made from aluminium 5xxx and
6xxx sheet for improved strength, the weight
saving amounts to 300 kg in the aluminium
body and 120 kg of the power train, altogether
420 kg, resulting in a total weight now of only
2,160 kg. This is equivalent to an 8% fuel efficiency
with improved vehicle dynamic.
From the standpoint of a strip rolling mill
the company Amag in Austria described its
expansion project ‘Amag 2014’ (see ALU-
MINIUM 6/2012, p. 16ff), in the implementation
of which Danieli played a decisive role.
Going round the workshop, the Forum participants
could see for themselves the huge size
and machining precision of the hot rolling
mill and 80-MN plate stretcher currently
being assembled. The stretcher is designed to
handle 25,000 tonnes of plate alloys per year
in the thickness range of 25 to 152.4 mm (6
inch) and 2,300 mm
in width. The product
range covers
aluminium alloys of
all series from 2xxx,
5xxx, 6xxx and 7xxx
alloys.
As another customer
of the Danieli
Aluminium Division,
the Russian
company KUMZ
(Kamensk Uralsky
Metallurgical Works)
introduced itself. The
company is one of
the few which, besides
Al-Mg based
alloys, also produces
Al-Li alloys, mainly
for the aviation industry.
As part of an
investment totalling
USD780 million, in
2014 Danieli will deliver a 6-high cold rolling
and a 1+1 hot rolling mill. The double stand hot
rolling mill represents an innovative new combination
plate and hot strip mill with roughing
stand and finishing mill in twin coiler configuration.
It will produce 4,300 mm wide plate,
2,800 mm wide strip and 3,500 mm wide coldrolled
sheet.
Downstream of the hot mill there will be
the world’s widest 6-high cold rolling mill,
featuring Danieli’s Diamond design. This mill
represents the latest cutting-edge rolling solutions
for aluminium aerospace products.
Another highlight of Danieli’s product
range are its advanced high speed edge trimming
and slitting lines for aluminium strip,
manufactured by Danieli Fröhling.
Fröhling has been marketing these units
for decades and has acquired an outstanding
reputation for them. Since 2003 the company
has delivered 40 complete cutting machines
and in the past two years alone 15 slitting and
edge trimming lines. Fröhling was the first to
manufacture slitting lines with 120 cuts. The
machines built today operate at speeds up to
1,800 m/min. What started with a typical trim-
56 ALUMINIUM · 11/2013

SPe CIAL
ALUMINIUM RoLLINg INDUSTRY
ming line 15 years ago, which was used to just
trim the strip edge, has now been adapted to
trimming lines for up to four finished strips.
This kind of combined trimmer with a slitting
function can operate at the same high speeds
as the conventional trimming lines.
Danieli’s expertise in aluminium heating
and heat treatment was introduced by Danieli
Olivotto Ferré. This company has over 80
years of experience and is a major European
producer of heating and heat treatment furnaces
for aluminium flat products. Recently
the company installed an innovative integrated
system of batch and continuous furnaces
for reheating and homogenising processes. Its
capability of offering flexible production and
energy efficiency became a benchmark for
modern flat rolled products.
Danieli’s heat treatment and coating lines
were introduced by Danieli Wean. The increase
in demand for heat-treatable automotive
alloys is changing the processing equipment
requirements with the necessity for
continuous thermal treatment of cold-rolled
aluminium sheet.
operational know-how – a key
factor for Danieli’s success
All aforementioned innovative aluminium
rolling technologies are technically supported
by Innoval Technology, which became part
of the Danieli Aluminium Strip Division in
2012 as a leading provider of independent
technical expertise to the global downstream
aluminium industry. Both companies see mutual
benefits in this move: for Danieli, the integration
of the Innoval team provides exclusive
added value for all the aluminium plants
it supplies. Innoval sees its position as technical
consultants to the world’s aluminium
rolling industry being strengthened by the
umbrella of a large manufacturing group. The
integration of Innoval into Danieli follows
five years of successful co-operation between
the two companies in the design and marketing
of the Danieli Fröhling Diamond Mill concept.
With the help of Innoval, Danieli can support
its customers selectively with their new
products, since new product lines have to be
monitored all along the entire process chain.
That begins with casting, progresses through
heating, heat treatment, hot and cold rolling,
and follows on with the slitting – all these
being processes that have different requirements
in relation to adjustment of the parameters
from one alloy to another. This demands
a profound knowledge of production, which is
available from Innoval.
In his closing address to this very first
Danieli Aluminium Symposium, Mr Alzetta
summarised that Danieli has now proven its
advanced technologies in various areas of the
aluminium production chain, some of them
being already in a market-leading position
such as the slitting and edge trimming lines
and the diamond rolling mills for automotive
products. Danieli will persist with its record of
product and processing innovation in accordance
with the group’s aforementioned mottos
‘innovaction’ and ‘we don’t shop around’.
As a final highlight Danieli announced that
Alcoa has recently chosen Danieli Fröhling
for a major revamp of its cold rolling mill in
Samara, Russia.
At the end of the Forum the participants
were shown round the Aleris Works in Duffel
and the first 6-high Diamond Mill for 2,300
mm wide automotive body sheet, supplied
by Danieli. This prestigious project was implemented
in a very short time of only 19
months, from order placement until the first
coil was rolled. Aleris expressed its complete
satisfaction and emphasised the excellent cooperation
with the Danieli team throughout
the entire project implementation period.
Author
Dipl.-Ing. Bernhard Rieth is a marketing specialist
and freelance technical journalist. As proprietor of
Marketing Xpertise Rieth in Meerbusch, Germany,
he advises equipment partners of the NF metals
semis industry on marketing-related matters.
Clean, low-cost reduction technologies on the horizon
Latest R & D project findings in the USA
could lead to universal changes in electrolysis
technology for conventional aluminium
cell reduction.
The Advanced Research Projects
Agency-Energy (ARPA-E) in the
USA has outlined its latest Award
schemes under new programmes that
provide options for a more sustainable
and secure American future
through supporting commercialisation
of new research results. In its
‘Metals’ category Light Metal Systems:
Technical Approach: Primary
Production – Aluminium, funds will
be directed to support the development
of new breakthroughs in primary
aluminium production.
Allocated a USD1 million funding
award under the scheme, Infinium, located in
Natick, Massachusetts, says that its innova-
Spent carbon anodes
tion, based on patented Pure Oxygen Anode
technology, provides a unique clean and lowcost
production route for aluminium.
In a parallel announcement and in recognition
of the process advantages, the Massachusetts
Clean Energy Centre (MassCEC) is
providing grant funding to match the ARPA-E
award in support of Infinium’s development
and commercialisation of this new reduction
technology. Prior to the grants, Infinium had
demonstrated an early-stage approach for primary
production of aluminium. The ARPA-E
award will enable the company to
apply its previous demonstration
work to develop a technology said
to operate at lower production cost
levels than electrolysis regimes conventionally
employed, using only half
the energy and generating virtually
no emissions. These process advantages
could transform the USD100
billion global aluminium production
market.
“Production of aluminium using
electrolysis has made only incremental
progress since the invention of
the Hall-Héroult process in 1880,”
comments Steve Derezinski, chief executive
of Infinium. “Our inert anodes make possible
ALUMINIUM · 11/2013 57

TeChNoLogY
Conventional carbon block anodes, assembled with rods
much more efficient system design, and we
are moving to accelerate development to address
the market’s need for a much cleaner,
lower cost approach to light metals pro-duction.
Support by both ARPA-E and MassCEC
validates the transforming nature of this technology,
and its ability to have a major impact
on how the world produces metals.”
Infinium is the sole manufacturer of metals
using Pure Oxygen Anodes, and has already
proven its capability to produce a range of
elements from their oxides, including magnesium
and titanium. Essentially the technique
using Infinium anodes involves separating
the metal production chamber from anode
gases, which eliminates contamination due
to corrosive and toxic anode gas contamination.
This uniquely reduces energy losses in
the electrolysis cell by 60% or more, and also
eliminates the extra collateral costs, energy
consumption and emissions associated with
conventional graphite anode production. The
company spotlights several key advantages
delivered through its technology in aluminium
production: It virtually eliminates CO 2
emissions, which currently amount to 7-10 lb
(3.18-4.54 kg) of CO 2 for every lb (0.454 kg)
of aluminium produced. Production output
per footprint is three to five times higher, and
total production costs are reduced by halving
the energy required and by eliminating the
need for consumable graphite anodes.
According to ARPA-E deputy director
Cheryl Martin, the prime objective of the
agency’s Metals programme is to identify costeffective
and energy-efficient manufacturing
techniques to process and recycle metals domestically.
She says: “We’re very excited to
see how our new awardees working on innovative
metals processing and recycling technologies
could create a breakthrough for
lightweight
vehicles and
energy applications.”
Infinium
is a development-stage
company
commercialising
novel
processes
for primary
production
and recycling
of metals,
chiefly those
with growing
demand in
energy efficiency
and renewable energy technologies.
The first two metals production routes it
investigated were magnesium, for lightweight
fuel-efficient vehicles and aircraft components,
and neodymium, for the magnets in
wind turbines and hybrid / electric vehicles.
Current primary production technologies for
these metals, Infinium recognised, are extremely
pollution-intensive negating much of
their benefit for clean energy and energy efficiency.
Infinium maintains that its new technology
efficiently produces these metals with
zero emissions.
Originally named Metal Oxygen Separation
Technologies (MOxST), the company
changed its name to Infinium in March this
year to reflect its key mission in sustainable
metals. Its facilities in Natick were recently
expanded, doubling its R & D capabilities, and
adding technology personnel.
Advanced electrolytic cell
with power modulation
and heat recovery
Another project has attracted a USD3 million
ARPA-E Award funding under the same
programme umbrella. Alcoa’s Technical
Centre in Pennsylvania is supported for its
work to develop what is said to be a highly
advanced electrochemical system for lowcost
and energy-efficient aluminium production.
The current smelter production process
used is energy intensive and loses a large
amount of thermal energy. This advanced
system will incorporate a high-cycle-life electrode
that is claimed to consumes less electricity
by incorporating innovative technology
which captures and reuses lost heat. If successful,
Alcoa’s electrochemical system will
produce bulk aluminium that requires less energy
with lower carbon emissions compared to
process routes conventionally used.
Dual electrolyte and
electrolytic membrane extraction
The US Gas Technology Institute (GTI) in Des
Plaines, Illinois, will also receive Award funding
to develop a new electrochemical process
that uses abundant, domestic ores to produce
aluminium powder at near room temperature.
Current US domestic aluminium smelters use
expensive foreign-sourced ore to produce
metal, and operate at high temperatures with
a significant amount of thermal energy loss.
GTI’s unique electrochemical process, it is
claimed, will require less energy and produce
fewer carbon dioxide emissions than conventional
smelters.
Conventional anode technology
In the aluminium reduction process conventionally
employed, large carbon block anodes
are used to conduct electricity. During operation
they are consumed, at a rate of around
450 kg a tonne of aluminium produced. The
two types of smelting technology in operation
today – Søderberg and Prebake – are characterised
by the types of anode used in each.
Søderberg smelters use a continuously created
anode, made by the addition of pitch to
the top of the electrolytic cell or ‘pot’. The
heat generated by the reduction process is
used to bake the pitch into the carbon form
required for reaction with alumina, thus recycling
the waste energy in the pot.
Prebake technology employs anodes,
which are baked in large-scale gas-fired ovens
at high temperature before being lowered
into the pot. These are then replaced once
consumed. The efficiency of this technology
compared to Søderberg, combined with its
lower environmental impact, means that prebake
smelters predominate (representing over
90% of worldwide aluminium production),
with all new facilities built today incorporating
this technology.
Ken Stanford, contributing editor
58 ALUMINIUM · 11/2013

TeChNoLogY
Advanced casting research to boost auto industry production
Metal casting process innovations will enable
new generations of high quality car
parts to be produced from recycled scrap
metal and derive more savings in natural
resources.
Further advances in solidification metallurgy related
to micro structures will boost casting integrity
and extend lightweighting options
Together with the careful control of metallurgical
process parameters and as-cast micro
structures, optimised conditioning and purification
of the molten metal are vital considerations
in casting aluminium, particularly from
recycled metal. The key objective is to ensure
the quality and integrity of foundry products
in a variety of applications, not least in the
automotive sector. Now, car makers in Britain
are likely to be the first to benefit from what
is hailed as revolutionary new metal casting
techniques developed at Brunel University
in London, through a UK Government-supported
programme to develop laboratory
discoveries for exploitation in industrial-scale
applications.
The £14 million Advanced Metal Casting
Centre (AMCC) at Brunel will bridge the gap
between fundamental research and full-scale
industrial trials. Along with the University, the
development is jointly funded by the Engineering
and Physical Sciences Research Council,
the aluminium automotive sheet and extrusions
solutions provider Constellium, and the
luxury car manufacturer Jaguar Land Rover.
The new facility will draw on the work carried
out by Professor Zhongyun Fan and his
university team at the Brunel Centre for Advanced
Solidification Technology to improve
the recyclability of metals. “Our long term
aim,” he says, “is to reduce the amount of new
metal mined from the ground to a minimum,
by finding ways to make high quality parts and
materials from metal that has already been
used at least once.”
“For example, in the UK alone we send
New AMCC at Brunel University – research work
programmes at the leading edge ...
around 300,000 tonnes of aluminium to landfill
every year. That is a direct economic loss
of nearly £800 million and represents a further
loss of around 11 million barrels of oil, representing
the energy used to make that amount
of aluminium. Clearly, there are many environmental
and economic benefits to be gained
from reusing that material.”
One project that will be pursued in the
AMCC is the replacement of the hundreds of
registered aluminium alloys currently in commercial
use with just over ten highly versatile
alloys that can be used over and over again.
Another research programme is aimed at
developing a set of very efficient techniques
for purifying and conditioning liquid metal to
support reliable industrial processes, that can
be used to make high quality castings for cars
and other applications. “Every failed casting
represents a huge waste of energy, time and
money,” says Professor Fan. “We know that
our new techniques can reliably create first
class components from recycled metal. Our
challenge now is to scale these methods up
for commercial use and to show that they can
reduce cost, improve quality, and conserve
natural resources.”
The basis for these new techniques generated
by the research work is essentially a
change in emphasis for the study of metal solidification.
The rate of cooling during metal
solidification has a key influence on gas porosity
and as-cast micro structure, including the
morphology of inclusions, which help to define
the subsequent mechanical and surface properties,
performance and integrity of the alloy
casting. The traditional approach has been to
look at the process of crystal growth as metal
cools, but this has been replaced with a focus
on nucleation, the effect that microscopic
impurities in the metal have on the solidification
process. By controlling the interface at
a microscopic level between the liquid metal
and the impurity particles, the characteristics
of the solidified metal casting can be manipulated
to produce the required properties. The
aim is to produce materials and components
with fine and uniform micro structure, uniform
chemical composition and reduced or
eliminated cast defects.
The AMCC will be housed in a 1,000 m 3
laboratory on Brunel’s campus in west London,
with industrial partners, including Constellium,
providing funding as well sponsoring
Research Fellows and providing technical support.
The centre will initially serve the automotive
industry, but the longer term aim is
to extend its knowledge to other engineering
sectors.
UK Minister for Universities and Science
David Willetts says: “For Britain to get ahead
in the global race we have to back emerging
technologies and ensure our universities have
... of aluminium casting technology
the latest equipment. This capital investment
will help scientists make new discoveries and
take their research through to commercial
success. It will drive growth and support the
Government’s industrial strategy.”
Ken Stanford, contributing editor
ALUMINIUM · 11/2013 59

TeChNoLogIe
Neue Montagehalle für Großmischer in Hardheim
© Eirich
Maschinenfabrik eirich feiert 150-jähriges Jubiläum
Die Maschinenfabrik Gustav Eirich
GmbH & Co. KG, Gründungsjahr 1863,
feiert in diesem Jahr ihr 150-jähriges
Jubiläum. Eirich ist ein Familienunternehmen,
das voll von seinen Mitarbeitern
getragen wird und nach Aussage der
Geschäftsführer 150 Jahre lang jung geblieben
ist. Diese beiden Faktoren sind
ein wesentlicher Teil des Erfolges dieses
Traditionsunternehmens.
In den Unternehmensleitlinien steht „Technologieführerschaft“
ganz weit oben. Eirich hat
erfolgreich über viele Jahrzehnte neue Verfahren
und neue Maschinen in seinen Kernmärkten
eingeführt. Aus rein mechanischem
Mischen haben sich in vielen Anwendungsbereichen
Verfahren entwickelt, die mehrere
Funktionen wie Trocknen, Kühlen, Heizen,
Pelletieren, Lösen, Kneten in einer Maschine
vereinen können.
Nach dem Motto „Erst schreiben wir die
Noten, dann suchen wir das dazu passende
Musikinstrument aus“ erarbeitet Eirich für
seine Kunden maßgeschneiderte Lösungen.
Die Vielzahl von Anwenderbranchen öffnet
Einblicke in Aufbereitungsmethoden, die innovativ
auf andere Branchen übertragen werden
können.
Das Unternehmen ist seit 1925 Partner der
Gießereien. Zu Beginn wurden Eirich-Formsandmischer
durch die Firma O. Ullrich, Leipzig,
bzw. nach dem 2. Weltkrieg durch Ullrich
& Roser, Bad Cannstatt, innerhalb der Gießereibranche
vertrieben. Seit 1965 entwickelt
und liefert Eirich selbständig Aufbereitungstechnik
für Formsande. Der Gießereiausrüster
hat in vielen Bereichen der Formsandaufbereitung
Pionierarbeit geleistet: Stichworte
sind kollerlose Formsandmischer, Online-
Qualitätsüberwachung der Formsandqualität,
Aufbereitungsanlagen in Turmbauweise, Mischen
und Kühlen unter Vakuum und vieles
mehr. Heute ist Eirich weltweiter Technologieführer
im Bereich der Formsandaufbereitung.
Forschung und Entwicklung haben bei Eirich
drei Säulen. Kundenspezifische Arbeiten,
erfahrungsbasierte Entwicklungen im eigenen
Haus sowie Zusammenarbeit mit Hochschulen
und Forschungsinstituten sind die
wesentlichen Quellen für Innovationen. Die
Ausgaben für F&E liegen laut Firmenaussage
wesentlich über dem Branchendurchschnitt.
Um möglichst nahe am Kunden zu sein,
hat Eirich in den vergangenen Jahrzehnten ein
internationales Netz von Vertriebs-, Produktions-
und Servicegesellschaften aufgebaut.
Frankreich, Russland, Ukraine, USA, Brasilien,
Südafrika, Indien, China und Japan sind
heute Eirich-Standorte. Einige der Auslandsgesellschaften
verantworten zusätzlich ein
eigenes Portfolio komplementärer Produkte,
die innerhalb der Firmengruppe auch für die
Zukunft weiteres Potenzial bereithalten. Alle
Produktionsgesellschaften der Eirich-Gruppe
produzieren mit großer Fertigungstiefe. Unabhängig
vom Standort werden auf diese Weise
Qualität und zuverlässige Auftragsabwicklung
gesichert.
Die Eirich-Gruppe befindet sich vollständig
im Familienbesitz. Sie zählt heute mit rund
1.500 Mitarbeitern und 200 Mio. Euro Umsatz
zu den größten Anbietern der Branche weltweit.
Umfangreiche Investitionen im In- und
Ausland unterstreichen die dynamische Weiterentwicklung
des Unternehmens.
Die Jubiläumsfeier fand im Juli im Kreis
der in- und ausländischen Mitarbeiter im Sinne
einer Familienfeier statt. Am 21. Juli wurde
zu einem Tag der offenen Tür am Firmensitz
in Hardheim eingeladen, zu dem auch das firmeneigene
Museum eröffnet wurde. Dieses
befasst sich mit der industriellen Entwicklung
von den Anfängen einer Mühlenwerkstatt hin
zu einem weltweit aufgestellten Maschinenbauunternehmen.
■
60 ALUMINIUM · 11/2013

A PPlicA tion
Ball Packaging bringt innovative Getränkedosen auf den Markt
© Ball
Ball Packaging Europe hat auf der
drinktec in München eine Reihe von Neuentwicklungen
vorgestellt, die Getränkedosen
und anderen Aluverpackungen
genau den emotionalen Mehrwert verleihen,
der den entscheidenden Kaufimpuls
auslösen kann.
Digital Window Printing: 36 verschiedene
Layouts in einem Produktionsdurchlauf – mit
dem neuen zweistufigen Digital Window Printing-Druckverfahren
können Getränkehersteller
Dosen mit unterschiedlichen Designs
gestalten. Zunächst werden herkömmliche
33 cl- und 50 cl-Aluminiumdosen hergestellt
und im Standardverfahren bedruckt, wobei ein
„Fenster“ ausgespart bleibt. Anschließend gehen
die Dosen durch die digitale Druckstraße.
Dort erhalten sie individuelle Designs, die exakt
in das freigelassene Fenster passen. Digital
Window Printing ermöglicht so eine individualisierte
Massenanfertigung bei der Dosenbedruckung
und ist daher die logische Antwort
auf den Trend zur Individualisierung.
Mit dem Sunlight Effect lassen sich auf der
Dosenwand bestimmte Gestaltungselemente
anbringen, die nur auf den zweiten Blick erkennbar
sind. Denn sie erscheinen erst, wenn
sie ins Sonnenlicht gestellt werden und UV-
Strahlen auf die Getränkedose fallen. Verschwindet
das UV-Licht, werden auch die
Bilder oder Textbotschaften wie von Zauberhand
wieder unsichtbar.
Silk & Shine Effect heißt eine neue Bedruckungstechnik
von Ball, die erstmals die Effekte
von Hochglanz und Mattdruck kombi-
Der Sunlight Effect lässt Bilder bei UV-Licht aufscheinen
/ The Sunlight Effect: pictures become visible
when UV light strikes the can
Ball Packaging launches innovative beverage cans
Digital Window Printing für individualisierte Designs
Digital window printing for individual designs
Ball Packaging Europe has presented
a number of new developments at this
year’s drinktec in Munich, providing beverage
cans and other aluminium packaging
with precisely the kind of emotional
value added that can trigger that all-important
purchase impulse.
Digital window printing: 36 different layouts
in one production run – the new two-stage
digital window printing process allows beverage
producers to present their cans with a
range of different designs. In the first step,
standard 33 cl or 50 cl aluminium cans are
produced the usual way, just leaving a ‘window’
unprinted. In the second step, the cans
are passed through the digital printing line
where customised designs are added to the
can, exactly fitting the window that was previously
left clean. The new technology is ideally
suited for actively engaging customers with
the brand, for example through seasonal promotions
or by submitting photos and designs.
Design elements printed on cans with the
new Sunlight Effect ink developed by Ball are
not noticeable at first glance. The designs become
visible when UV light strikes the beverage
can. When the UV light disappears, the
images or text vanish – like magic.
Silk & Shine Effect is a new Ball coating
technology that for the first time creates a
powerful contrast by combining the effects of
high gloss and matte printing. Certain areas
and design elements on the surface of the can
have a special tactile-like effect. By combining
two printing processes Ball creates visual and
haptic effects.
The Neon Effect creates an intense neonyellow
for enhancing can designs. A new ink
pigment produces a striking colour effect
and adds sharp, vibrant contrasts – especially
against a black background. This design element
is particularly suitable for energy drinks,
because the yellow colour itself is packed with
energy.
The Easy Flow End beverage can features
an additional air vent under the tab that can
be easily pierced with an object at hand, such
as a key. The second opening guarantees a
smoother flow of the contents especially when
poured and draws attention to the liquid itself.
Up until now, pouring from a can was accompanied
by a ‘glugging’ effect. The tiny air vent
completely eliminates this effect and ensures
smooth pouring which has become a hot topic,
especially in the brewery industry.
Expanded product range: With two new
can sizes, Ball Packaging Europe expands the
opportunities for manufacturers to market
their products in the perfectly sized container
Der Neon Effect bietet scharfen, leuchtenden Kontrasten
/ The Neon Effect adds sharp, vibrant contrasts
to match drink and consumer with the situation
in which the drink is enjoyed. While the
35.5cl Sleek can has a slender silhouette and
is nice to hold, the XL can contains nearly
a litre (946 ml) and is ideal for sharing with
friends at home or at parties.
Ball develops lightest 50 cl can
Ball has developed the world’s lightest 50 cl
aluminium beverage can: the sealed B-Can is
ALUMINIUM · 11/2013 61

AnwendunG
niert. Zudem lassen sich bestimmte Bereiche
oder Gestaltungselemente auf der Dosenoberfläche
„fühlbar“ betonen. Durch die Kombination
zweier Druckverfahren im Silk & Shine
Effect werden visuelle und haptische Effekte
erzeugt.
verfügt direkt unter der Deckellasche über
eine zweite, kleine Öffnung. Der Konsument
kann sie mit einem Gegenstand – beispielsweise
einem Schlüssel – ganz einfach aufstoßen.
Die zweite Öffnung ermöglicht einen gleichmäßigen
Fluss des Getränks beim Ausgießen.
Bisher entstand beim Ausgießen aus der Dose
häufig eine Art „Gluck-Effekt“, der nun dank
der Zweitöffnung ausbleibt.
Erweitertes Sortiment: Mit zwei neuen Dosenformaten
bietet Ball Getränkeherstellern
neue Möglichkeiten, ihre Produkte zu vermarkten
und die Gebinde optimal an Zielgruppen
und Konsumsituationen anzupassen. Die
35,5 cl-Sleek-Dose ist schmal und sehr handlich,
die XL-Dose mit einem Volumen von fast
einem Liter (946 ml) speziell für Partys und
zum Genuss mit Freunden geeignet.
five percent lighter than a standard beverage
can, thus improving the environmental footprint
of beverage cans. At first glance, five
percent may seem like a minimal reduction
in the amount of material used. But it makes
a big difference. Replacing all 33 cl and 50 cl
aluminium cans in Europe with the ultra-light
model produced by Ball would save about
19,000 tonnes of aluminium each year. This is
roughly equivalent to the weight of 100 jumbo
jets.
■
Easy Flow End für besseres Ausgießen
Easy Flow End for better pouring
Mit dem Neon Effect lassen sich Getränkedosen
in einem intensiven, neonfarbenen Gelbton
gestalten. Ein neues Pigment in der Druckfarbe
erzeugt dabei den auffallenden Farbeffekt.
Vor allem vor einem schwarzen Hintergrund
lassen sich damit scharfe, besonders leuchtende
Kontraste erzielen. Der Neon Effect bietet
sich als wirkungsvolles Gestaltungselement
speziell bei Energy-Drinks an.
Der Getränkedosendeckel Easy Flow End
Ball entwickelt leichteste 50 cl-dose
Mit der „B-Can“ hat Ball eine Dose entwickelt,
die mit Deckel rund fünf Prozent
weniger als eine Standarddose wiegt. Dies
verbessert den ökologischen Fußabdruck von
Getränkedosen, denn die auf den ersten Blick
minimal wirkende Materialeinsparung summiert
sich in der Massenproduktion: Bei einer
europaweiten Umstellung aller 33 cl- und
50 cl-Aludosen auf die ultraleichten Varianten
von Ball ließen sich jährlich rund 19.000
Tonnen Aluminium einsparen. Das entspricht
ungefähr dem Gewicht von 100 Jumbo-Jets.
■
XL-Dose für den Partyspaß
XL can – ideal size at a party
Aluminium smelting industry
© Dubal
Aluminij Mostar forced into bankruptcy
Aluminij Mostar in Bosnia is bankrupt after all
bank accounts were blocked. The company has
started shutting down its smelter. In an Open
Letter to the political leadership of Croatia,
Aluminij CEO Ivo Bradvica says power utility
EPHZHB has insisted in “demanding immediate
payments of our debts”, amounting to
about KM38m (editor’s note: €19m), which
the company is unable to pay at present. The
debts of 38m Bosnian marka refer to invoices
of the last 3.5 months alone. The smelter
suffers from low aluminium prices and high
power costs. Power accounts for about 60%
of Aluminij’s production costs.
Aluminij accounts for more than 25% of
Bosnia’s GDP. The government has already
saved the company from collapse in June by
taking a 44% share and promising further
subsidies. Mr Bradvica is in hope of support
by Nermin Niksic, prime minister of Bosnia’s
autonomous Muslim-Croat Federation, which
owns 98% of EPHZHB. Nikola Kresic, director
of the power utility, said to local media the
company had been forced to block Aluminij’s
accounts “because our operation was endangered
by this debt.”
62 ALUMINIUM · 11/2013

coMPAny news worldwide
Aluminij produces around 160,000 tpy of aluminium
and employs 900 people directly in
the Mostar region.
KAP declared bankrupt by court
Aluminium producer KAP (Kombinat Aluminijuma
Podgorica), the largest industrial
company in Montenegro, has officially been
declared bankrupt by court. The deadline to
submit plans for restructuring KAP had expired,
judge Dragan Rakocevic said to journalists.
The company will be offered for sale
early in November in the hope of repaying at
least some of the huge debts to creditors: the
talk is of €360m-460m in liabilities. KAP’s
largest creditors are the Montenegrin government
and the Central European Aluminium
Co. (CEAC), an arm of En+ Group which is
controlled by Russian billionaire Oleg Deripaska.
The Montenegrin government and CEAC
each own 29.36% of KAP. Further creditors
are foreign banks, including Deutsche Bank,
Hungarian OTP and Russian VTB.
About 1,200 employees are affected by
the bankruptcy. Last year KAP accounted for
4.7% of Montenegro’s GDP and for 30% of
the country’s exports.
rtA demands lower
energy prices in Quebec
Rio Tinto Alcan (RTA) demands that energy
prices be made more competitive to bolster
industrial growth in Quebec. During the Public
Consultation on Energy Issues in Quebec,
the company said that Quebec’s energy policy
must affirm the province’s resolution to offer
lower energy prices for the growth of its
manufacturing sector, including the aluminium
industry. President and CEO of Primary
Metal, Arnaud Soirat, pointed out: “The
world’s most competitive economies rely on
a strong manufacturing sector that fosters
employment growth, provides good wages,
positively influences the trade balance of an
economy and invests more in research and
development than any other sector.” In this
regard, RTA considers the aluminium industry
as a long-term strategic choice for Quebec.
Étienne Jacques, COO of the Primary Metal
division, North America, added: “At the current
energy prices, over three-quarters of the
world’s aluminium smelters benefit from rates
that are lower than Hydro-Québec’s rate for
large industrial users.”
The company agrees in several of the objectives
set out in the Consultation paper.
For example, on greenhouse gas emissions
(GHG), the company exceeds the reduction
targets set out in the Kyoto Protocol. Since
1990, RTA’s aluminium production has increased
by 50% while its GHG emissions
were reduced by 50%. A competitive energy
price would encourage production of aluminium
with the world’s lowest GHG emissions
levels.
Hydro seeks support for pilot plant
Hydro has asked Enova for financial support
in connection with a project to test next-generation
aluminium electrolysis technology at
a pilot plant in Karmøy, Norway. The plant will
have a production capacity of 70,000 tpy with
the aim of testing further developed energyefficient
aluminium cell technology in a fullscale
industrial environment. The Norwegian
government-owned organisation Enova has
established a programme to support energyand
climate-related technology in industry.
Hydro and Enova have been in talks on
how to realise pioneering technology that can
reduce energy consumption and emissions
from Norwegian industry. A 70,000-tonne
pilot plant in the application is estimated to
cost about NKr 3.5bn (€446m). Hydro has applied
for support under Enova’s programme
for climate technology totalling about half the
sum over a four-year period. If the project is
realised, Karmøy will host one of the most
energy-efficient aluminium smelters in the
world. Such a plant could begin production
in 2017.
rusal to invest in the
environmental upgrade of irkAZ
UC Rusal plans to invest RUR367.9m in
modernising gas treatment equipment at the
Irkutsk aluminium smelter (IrkAZ). According
to the emissions reduction plan, approved by
the Ministry of natural resources of the Irkutsk
region, between 2013 and 2015, seven electrostatic
precipitators in the third and fourth
potlines and six foam-type scrubbers in the
third potline will be replaced at the smelter.
An electrostatic precipitator in Potline 4
was replaced with a new horizontal-type
precipitator already in October this year. The
cost of the project amounted to RUR60m.
Another electrostatic precipitator is planned
to be installed in Potline 4 in 2014. The new
equipment is 5% more efficient and will capture
up to 99% of particulate fluorides and
potroom dust. Three foam-type scrubbers
have been replaced in Potline 3 and the fourth
scrubber is to be installed by the end of this
year. This will result in the capture of at least
98.5% of hydrogen fluoride (HF) and sulphur
dioxide emissions, reduce energy consumption
and decrease the cost of foam-type scrubbers’
cleaning.
The environmental upgrade will also see
the completion of construction at section No
2 of the red mud disposal area No 3, creating
a storage area for liquid production waste,
reducing the risk of pollution of soil and underground
waters.
ormet shuts down Hannibal operations
US aluminium company Ormet, based in
Hannibal / Ohio, announced in October that
it would immediately shut down operations
after the Public Utilities Commission of Ohio
(Puco) had denied Ormet’s request for an energy
transition plan that would allow it to operate
while constructing an onsite natural gas
based power generation facility. Due to this
decision, Ormet cannot emerge from bankruptcy.
Ormet was forced to file for bankruptcy
in February this year due to low metal prices
and high and uncontrollable power costs. The
Ohio Power industrial rate which establishes
the base rate for Ormet to procure power has
increased from USD39.66/MWh, when the
Unique Arrangement (UA) was established in
2009, to USD60.83/MWh in September 2013,
which is an increase of over 53%. During the
same period, wholesale power costs in the
region have decreased by over 10%. At full
operations, Ormet’s projected 2014 energy
cost would reflect an increase of USD108m,
before the potential discount of USD54m as
provided for in the Puco ruling.
➝
the Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the primary
aluminium industry. He is also the publisher
of the standard works Alumina Refineries and
Producers of the World and Primary Aluminium
Smelters and Producers of the World. These
reference works are continually updated, and
contain useful technical and economic information
on all alumina refineries and primary
aluminium smelters of the world. They are
available as loose-leaf files and / or CD-ROMs
from Beuth-Verlag GmbH in Berlin.
ALUMINIUM · 11/2013 63

coMPAny news worldwide
rusal: interim result of production cuts
UC Rusal has announced interim results of
the production volume reduction programme
at its least efficient smelters. As of mid-October,
aluminium production has been mothballed
at the Volgograd (VgAZ), Urals (UAZ),
and Volkhov (VAZ) aluminium smelters, as
well as at the first phase of the Novokuznetsk
(NkAZ) smelter and at the Alscon smelter in
Nigeria. Furthermore, aluminium production
has been mothballed at the Bogoslovsk (BAZ)
potrooms 2-5 (potroom 1 was shut down in
2011) and at the Nadvoitsy (NAZ) potrooms
1-2 (potroom 3 was shut down in 2012). Output
reduction in 2013 at the above-mentioned
facilities will amount to 247,009 tonnes, and
will result in an output decrease of 516,062
tonnes in 2014.
Due to various measures taken by Rusal
such as amperage reduction, production
volume at the Sayanogorsk (SAZ), Irkutsk
(IrkAZ), Novokuznetsk (second phase) and
Khakass (KhaZ) aluminium smelters has decreased.
Output reduction in 2013 at these
smelters will amount to 77,724 tonnes with an
expected effect of 131,442 tonnes in 2014.
As a result of the output reduction programme,
Rusal has already cut aluminium
production by 324,733 tonnes, or 8% of 2012
production volume, with an effect of 647,504
tonnes, or 15% of 2012 production volume,
in 2014. These measures have allowed the
company to realise savings of USD40/t Al in
cash cost. “RUSAL continues to react to the
current market conditions and may consider
further actions to improve its cost position
in the industry,” said Vladislav Soloviev, the
company’s first deputy CEO.
Also, due to the prevailing market conditions,
investors of the BEMO project have
taken the decision to delay the start of the
commissioning of the Boguchansky smelter
until mid-2014.
rusal and VeB to develop new products
UC Rusal has signed a Memorandum of Intent
(MoI) with the State Corporation ‘Bank for
Development and Foreign Economic Affairs
(Vnesheconombank, VEB) to convert Rusal’s
loss-making smelters. Rusal and VEB intend
to work together to create production facilities
to produce automotive components made
of aluminium and its alloys as well as rolled
and cable products. The finished goods are
intended to be supplied to the Russian market.
For example, both Russian and foreign
carmakers, who have certain commitments to
increase the share of Russian-made parts used
by their facilities, will be among the potential
consumers of such components. As a party to
the agreement Rusal is ready to attract investors,
provide them with the existing industrial
infrastructure and ensure that aluminium is
supplied to production sites.
VEB in turn will consider its participation
in investment projects which have been proposed
by Rusal and that are in line with the
bank’s investment and financial policies. The
new facilities will be sited at the Bogoslovsk,
Urals, Nadvoitsy, Kandalaksha, Volkhov and
Volgograd aluminium smelters or at other
plants located in the respective federal subjects
of Russia.
Rusal has already started converting its
loss-making facilities with the signing of a
MoU with the Israeli company Omen High
Pressure Die Casting. This memorandum outlines
details of the creation of a joint venture
to produce automotive components. The joint
venture will be sited at the Volkhov aluminium
smelter.
Venezuela supports Alcasa smelter
on the move
Graeme Bottger has been named executive vicepresident
and president of Global Business Services
(GBS) of Alcoa. Assistant controller Robert
Collins will succeed Bottger as vice-president and
controller. Mark Davies, who has been president
of GBS since 2012, leaves the company.
Heinz Peter Schlüter has been elected the
new president of the German aluminium association
GDA.
Former Rio Tinto CEO Tom Albanese is
joining the Vedanta Group as chairman of subsidiary
Vedanta Resources Holding. In this role,
Albanese will be actively involved in continuing
to develop the company’s strategy, policies and
growth objectives.
The LME’s new CEO Garry Jones took on his
role on 30 September.
President Barack Obama has tapped Alcoa
chairman and CEO Klaus Kleinfeld to join the
President’s Advanced Manufacturing Partnership
Steering Committee 2.0. This is part of a
The Venezuelan government has injected
22m bolívares (USD3.49m) for equipment
and installation investments at Corporación
Venezolana de Guayana Alcasa (CVG Alcasa).
The state-owned producer intends to restart
230 pot cells to reach a total of 389 in operation
by 2014, and so to achieve a primary
aluminium output of 170,000 tpy. Alcasa was
heavily affected by an energy crisis in Venezuela
in 2010/11, which led the company to
shut down more than half of its then 600 cells
as part of a programme to save energy.
slovalco and se agree on power contract
Slovak aluminium producer Slovalco and the
country’s power utility Slovenske Elektrarne
(SE) have agreed on a new long-term power
supply contract. SE will supply a total of 19
TWh of electricity to Slovalco for a period of
eight years starting from January 2014 at discount
prices, which were not disclosed. Slovalco’s
current contract at fixed prices with SE
expires at the end of this year. The aluminium
producer has previously said that if it buys
electricity at market prices this would threaten
the viability of its operations.
Slovalco is majority owned by Norwegian
aluminium group Hydro, which holds a
55.3% stake, while Slovak company ZSNP
SCO holds the balance of 44.7%. Its aluminium
production plant in Ziar nad Hronom, central
Slovakia, employs about 3,000 people.
The Slovak government, which owns a
34% stake in SE is in the process of completing
several other steps in order to prevent a
closure of the aluminium smelter. It will pay
about half of the plant’s electricity transmission
charges, contributing €36m a year, but
continuing effort to maintain US leadership in
the emerging technologies that will create highquality
manufacturing jobs and enhance America’s
global competitiveness.
Rusal has appointed Evgeny Nikitin director
of the Aluminium Division East. Mr Nikitin has
been managing director of the Krasnoyarsk Aluminium
Smelter since 2010. Alexandra Buriko has
been appointed CFO. She is responsible for financial
planning, auditing, preparation of financial
reports and execution of the cmpany’s investment
programmes. Evgeny Kornilov’s term as Rusal’s
CFO has ended with the expiry of his contract.
Albrecht Neumann will assume the position
of CEO of the Sector-led Metals Technologies
business unit at Siemens. He will succeed Werner
Auer, who is leaving the company for personal
reasons. Until now, Mr Neumann has been the
CEO of Siemens Metals Technologies in the
United States, with responsibility for the North
American business of Metals Technologies.
64 ALUMINIUM · 11/2013

coMPAny news worldwide
the amount could grow to more than €50m if
Slovalco decides to boost production and use
more energy. The cabinet is also due to approve
a proposal to grant Slovalco a €5m discount
on its yearly payments to the National
Nuclear Fund.
Slovalco has become the fourth company
that the Slovakian government is supporting
in order to avoid large job losses after steel
mill US Steel Kosice, electronics maker Samsung
and pulp and paper manufacturer Mondi
SCP. The aluminium smelter has a production
capacity of around 165,000 tpy.
Aluminium semis
will be used to produce the 7.7m tpy needed
for the alumina plant. In addition, Pará state
will provide investment opportunities through
partnerships with private businesses in an effort
to improve local industrial development.
In May 2013, Norwegian aluminium producer
Norsk Hydro, whose global operations
include the world’s largest alumina refinery
Alunorte in Pará, was one of the first companies
to enter into a partnership with the state
and signed an agreement. Following Hydro,
Alcoa signed the protocol in September. Pará
is the only Brazilian state in control of all stages
of the aluminium production chain.
VM currently has four aluminium production
plants. Bauxite produced in three of these
plants is shipped to its Alumínio plant, which
can produce 475,000 tpy of aluminium. ■
iran to invest over 8bn
euros in aluminium sector
Iran plans to invest around 8.5bn euros
(USD11.4bn) in its aluminium industry in
order to nearly quadruple production by
2025. According to a senior manager of Imidro
(Iranian Mines and Mining Industries Development
and Renovation Organisation) at
a Metal Bulletin conference in Geneva, aluminium
demand in Iran grows 10% a year.
The country produced 338,000 tonnes of aluminium
in 2012, and is aiming for 770,000
tonnes in 2016 and 1.5m tonnes by 2025.
There are eight projects involved in the investment
programme, with bidding underway
for the Persian Gulf Alumina plant, and financing
being arranged for two others (Salco,
Kalco).
■
Bauxite and
alumina activities
Votorantim Metais signs loi
with Pará’s mining industry
Brazilian metals producer Votorantim Metais
(VM) has signed a letter of intent with Brazil’s
Pará state industry, commerce and mining
department (Seicom) as part of the state’s
effort to attract at least ten new companies to
its mining and metals industry by 2014. According
to the letter, VM wants to provide the
state’s municipality of Rondon do Pará with
adequate infrastructure to receive the company’s
Alumina Rondon project as well as to
help develop Pará state.
Alumina Rondon will be VM’s major
project and one of the largest in Pará state, as
its bauxite mine will be completely integrated
with the alumina refinery. The company will
start operations at the bauxite mine, which
rexam to open a new can line in chile
Beverage can maker Rexam plans to open a
second production line at its plant in Santiago,
Chile. The plant will then have the capacity
to produce 1.9bn cans a year, which is an
increase of 72% compared with the current
production volume. The new line will produce
350 ml, 473 ml and 250 ml sizes and is a step
further for Rexam to increase its offer of specialty
cans in South America, as the plant in
Chile also supplies the markets of Peru and
Bolivia. This region has been reporting consistent,
continuous economic growth and still has
great potential for the coming years.
Only recently, in May, Rexam opened a
new can plant in Brazil, with a production
capacity of 800m cans a year.
Alcoa to sell French and
spanish rolling mills
Alcoa plans to sell its sole rolling mill in France
as well as two rolling mills in Spain, the head
of the French plant recently told a local newspaper.
In case that selling the plants fails Alcoa
will continue operations as the sites are profitable.
Alcoa says it is convinced the sites have
potential, but given funding constraints the
company is looking for another owner.
The three plants are interlinked and form a
single system. The factories in Amorebieta
and Alicante in Spain makes rolled products
for Castelsarrasin to turn into polished aluminium.
The Amorebieta site near Bilbao
employs 401 people while 294 work at the
Alicante facility. The Castelsarrasin plant has
41 employees.
Alcoa may also sell its Canadian rod mill
at Bécancour, Québec, as well as its Fjardaál
rod mill in Reyðarfjörður, Iceland, Metal Bulletin
reported. The Bécancour rod mill, near
Intralogistik-Lösungen
neu im Internet unter
www.herrmannhieber.de
the St Lawrence River, opened in 1992 and
cost USD49m to build. The facility makes pure
aluminium or aluminium alloy rod for the
electric cable sector, for magnetic wire manufacturers
and for steel mills. The Bécancour
rod plant sources its molten metal from Alcoa’s
majority-owned Aluminerie de Bécancour.
It boasts a fully automated rolling mill
and continuous casting facility, and is capable
of making 12.5 tph of rod.
■
➝
© Hydro
ALUMINIUM · 11/2013 65

coMPAny news worldwide
suppliers
sapa Profiles orders frontloading
press from sMs Meer
Sapa Profiles from Székesfehérvár, Hungary,
has placed an order with SMS Meer, Germany,
for the delivery of a 32/35-MN short-stroke
front-loading press. Thanks to the optimised
hydraulic system, the plant offers short downtimes
and a high level of productivity.
Impressive features of this fully automated
front-loading press include a compact, stable
press frame and short cylinder strokes. Further
benefits are the energy-efficient design of the
hydraulic drive unit. Unnecessary drives are
deactivated by means of a newly developed
system. Compared with older presses Sapa
thereby saves a large amount of energy.
The press will be used to process nine inch
billets in a range of lengths
from 350 to 1,300 mm.
The tool package allows
rounds of up to 300 mm
in diameter and flats with
a width of up to 400 m to
be produced. The plant’s
non-productive time including
unloading is just
12.4 seconds.
SMS Meer will integrate
the new press seamlessly
into the existing Speedex
visualisation system at
Sapa that is used for the
input, display and saving
of all desired and actual
parameters for the whole
extrusion line. Commissioning
is scheduled for
February 2014. ■
Sapa Profiles has ordered a comparable press from SMS Meer
© SMS Meer
Patentblatt August 2013
Fortsetzung aus ALUMINIUM 10/2013
Verfahren zum Kombinieren von Schweißen
und Kleben zur Verbindung von Metallteilen.
Alcoa Inc., Pittsburgh, Pa., US. (B23K 28/00,
PS 60 2004 038 606, EP 1660270, WO 2005/
021207, AT: 30.08.2004, EP-AT: 30.08.2004,
WO-AT: 30.08.2004)
Geformter Metallbehälter und Verfahren zu
seiner Herstellung. Alcoa Inc., Pittsburgh, PA
15212-5858, US. (B21D 51/26, EPA 2605873,
WO 2012/024671, EP-AT: 22.08.2011, WO-AT:
22.08.2011)
Verfahren zur Herstellung eines Automobil-
Strukturteils aus einer gewalzten AlZn-Legierung.
Aleris Aluminum Duffel BVBA, Duffel,
BE. (C22C 21/10, WO 2012 059505, AT: 02.11.
2011, WO-AT: 02.11.2011)
Erweiterungsprofil für Befestigungsanker.
Alcoa Aluminium Deutschland, Inc., 58642 Iserlohn,
DE. (E06B 1/60, EPA 2612978, EP-AT:
19.12.2012, WO-AT: 19.12.2012)
Plattiertes Blechprodukt. Aleris Aluminum
Duffel BVBA, Duffel, BE. (B32B 15/01, EP 2 052
851, AT: 19.04.2007, EP-AT: 19.04.2007)
Lötvorflussbeschichtung. Norsk Hydro ASA,
0240 Olso, NO. (B23K 1/20, EPA 2608919,
WO 2012/026823, EP-AT: 22.08.2011, WO-AT:
22.08.2011)
Verfahren zur Herstellung eines Absorberblechs
für Sonnenkollektoren, nach dem Verfahren
hergestelltes Absorberblech und dessen
Verwendung. Hydro Aluminium Deutschland
GmbH, 41515 Grevenbroich, DE. (B05D 7/14,
PS 10 2006 039 804, AT: 25.08.2006)
Band für lithografische Druckplattenträger.
Hydro Aluminium Deutschland GmbH, 41515
Grevenbroich, DE. (B41N 1/08, GM 20 2006 021
140, AT: 21.07.2006)
Beheizbare Bade- oder Duschwanne. Hydro
Aluminium Deutschland GmbH, 41515 Grevenbroich,
DE. (F24H 1/00, EP 2 072 930, AT:
17.12.2008, EP-AT: 17.12.2008)
Vorrichtung zur Halterung von Bauteilen.
Erbslöh AG, 42553 Velbert, DE. (F16M 11/20,
GM 20 2010 007 497, AT: 02.06.2010)
Vorrichtung zum kontinuierlichen Gießen von
Metallblöcken. Novelis, Inc., Toronto, Ontario,
CA. (B22D 11/14, EP 2 058 064, AT: 09.12.
2004, EP-AT: 09.12.2004)
Kolben einer Brennkraftmaschine mit unterschiedlichen
Größen des Alpha-Mischkristalls.
KS Kolbenschmidt GmbH, 74172 Neckarsulm,
DE. (B22D 27/20, OS 10 2006 040 046, AT:
26.08.2006)
Vollständig im Schmiedeverfahren hergestellter
Kolbenrohling eines Kühlkanalkolbens. KS
Kolbenschmidt GmbH, 74172 Neckarsulm, DE.
(B23P 15/10, OS 10 2013 201 927, AT: 06.02.
2013)
Verfahren zur Erzeugung einer Aluminiumstruktur
und Aluminiumstruktur. Sumitomo
Electric Industries, Ltd., Osaka, JP. (C25D 1/08,
WO 2012 039287, AT: 08.09.2011, WO-AT:
08.09.2011)
Kolben für einen Verbrennungsmotor und
Verfahren zu seiner Herstellung. Mahle International
GmbH, 70376 Stuttgart, DE. (F02F 3/00,
EPA 2603685, WO 2012/019592, EP-AT: 09.08.
2011, WO-AT: 09.08.2011) sowie (B23K 20/12,
EPA 2603347, WO 2012/019595, EP-AT:
09.08.2011, WO-AT: 09.08.2011) sowie (F02F
3/18, OS 10 2006 027 355, AT: 13.06.2006)
Verfahren zur Herstellung eines Magnesiumlegierungsprodukts.
Sumitomo Electric Industries,
Ltd., Osaka, JP. (B21B 1/16, PS 60 2005 035
133, EP 1775037, WO 2006/003833, AT: 23.06.
2005, EP-AT: 23.06.2005, WO-AT: 23.06.2005)
Verfahren zur Herstellung eines Kolbens für
einen Verbrennungsmotor sowie Kolben für
einen Verbrennungsmotor. Mahle International
GmbH, 70376 Stuttgart, DE. (B23P 15/10, EPA
2603348, WO 2012/019593, EP-AT: 09.08.2011,
WO-AT: 09.08.2011)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/00, EPA 2603686, WO 2012/019594, EP-AT:
09.08.2011, WO-AT: 09.08.2011)
Verfahren zur Herstellung eines einteiligen
Kolbens für einen Verbrennungsmotor. Mahle
GmbH, 70376 Stuttgart, DE. (F02F 3/22, PS 50
2004 013 662, EP 1636474, WO 2004/103634,
AT: 18.05.2004, EP-AT: 18.05.2004, WO-AT:
18.05.2004)
Aluminiummaterial für eine Elektrode eines
elektrolytischen Kondensators, Verfahren zur
Herstellung. Showa Denko K.K., Tokio, JP. (C22C
21/00, PS 60 2005 035 460, EP 1841892, WO
2006/068300, AT: 21.12.2005, EP-AT: 21.12.
2005, WO-AT: 21.12.2005)
Wärmetauscher, umfassend ein Aluminiumrippenmaterial,
und Herstellungsverfahren für
diesen Wärmetauscher. Denso Corp., Kariyacity,
Aichi-pref., JP; Sumitomo Light Metal Industries,
Ltd., Tokio, JP. (B23K 35/28, PS 103 27 755,
AT: 18.06.2003)
66 ALUMINIUM · 11/2013

PAtente
Patentblatt september 2013
Zubereitung von Cu-Al-Kataslysatoren. BASF
Catalysts LLC, Florham Park, N.J., US. (B01J 23/
72, PS 697 40 475, EP 0888185, WO 1997/
034694, AT: 21.03.1997, EP-AT: 21.03.1997,
WO-AT: 21.03.1997)
Verfahren zur Herstellung von gegenüber Wasser
reaktivem Al-Film und Bauelement für Filmbildungskammer.
ULVAC, Inc., Chigasaki-shi,
Kanagawa, JP. (C23C 4/06, PS 60 2009 008 849,
EP 2280091, WO 2009/133841, AT: 7.04.2009,
EP-AT: 27.04.2009, WO-AT: 27.04.2009)
Knetprodukt in Form eines gewalzten Blechs
und Strukturbauteil für Flugzeug aus Al-Zn-
Cu-Mg-Legierung. Constellium France, Paris,
FR; Constellium Rolled Products Ravenswood,
LLC, Ravenswood, W.Va., US. (C22C 21/10, PS
60 2004 039 009, EP 1544315, AT: 15.12.2004,
EP-AT: 15.12.2004).
Verfahren zum Erreichen verbesserter epitaxialer
Qualität (Oberflächenstruktur und
Defektdichte) auf freistehenden (Aluminium,
Indium, Gallium) Nitrid ((Al, In, Ga)N)-Substraten
für optoelektronische und elektronische
Vorrichtungen. Cree, Inc., Durham, N.C., US.
(C30B 23/02, EP 2 290 135, AT: 27.06.2001,
EP-AT: 27.06.2001) sowie (C30B 23/02, PS 601
47 031, EP 2284297, AT: 27.06.2001, EP-AT:
27.06.2001)
Verfahren zur Herstellung einer geformten
Verkleidung aus einer Al-Legierung für Anwendungen
in der Luft- und Raumfahrt. Aleris
Rolled Products Germany GmbH, 56070 Koblenz,
DE. (C22C 21/06, WO 2012 079828, AT:
28.10.2011, WO-AT: 28.10.2011)
Hexagonaler Mischkristall aus einem Al-Cr-O-
N-Stoffsystem. Karlsruher Institut für Technologie,
76131 Karlsruhe, DE. (C01G 37/02, PS 10
2010 011 694, AT: 17.03.2010)
Lackaufbau für Aluminium. Siemens AG, 80333
München, DE. (C09D 143/04, OS 10 2012 203
385, AT: 05.03.2012)
ALUMINIUM veröffentlicht unter dieser Rubrik
regelmäßig einen Überblick über wichtige,
den Werkstoff Aluminium betreffende
Patente. Die ausführlichen Patentblätter und
auch weiterführende Informationen dazu
stehen der Redaktion nicht zur Verfügung.
Interessenten können diese beziehen oder
einsehen bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
Al-Legierungs-Sputtertarget und Herstellungsverfahren
dafür. Kabushiki Kaisha Kobe Seiko
Sho, Chuo-ku Kobe-shi Hyogo 651-8585, JP;
Kobelco Research Institute , Inc., Kobe-shi Hyogo
651-0073, JP. (C23C 14/34, EPA 2626443,
WO 2012/046768, EP-AT: 05.10.20119, WO-
AT: 05.10.2011)
Dichtungsecke aus einseitig selbstklebendem
Butyl-Kautschuk mit auf der Rückseite aufgebrachter
Aluminiumabdeckung zum Abdichten
des Inneneckbereiches von Aufsteckflanschen
an eckigen luftführenden Bauteilen von raumlufttechnischen
Anlagen. airleben GmbH, 99867
Gotha, DE. (F24F 13/02, GM 20 2013 000 040,
AT: 10.01.2013)
Elektrische Verbindungsvorrichtung für eine
Verbindung zwischen zwei aufeinander folgenden
Zellen einer Zellreihe zur Herstellung
von Aluminium. Rio Tinto Alcan Intl Ltd,
Montréal, QC H3A 3G2, CA. (C25C 3/16, EPA
2616571, WO 2012/035212, EP-AT: 06.09.
2011, WO-AT: 06.09.2011)
Elektrolysezelle zur Gewinnung von Aluminium.
SGL Carbon SE, 65201 Wiesbaden, DE.
(C25C 3/06, EPA 2619350 u. EP 2619351,
WO 2012/038423 u. WO 2012/038426, EP-AT:
20.09.2011, WO-AT: 20.09.2011)
Neuartige kombinierte, graphitierte heterotype
Kathode zur Gewinnung von Aluminium
und deren graphitierter Kathodenhemmblock.
Guangxi Qiangqiang Carbon Co. Ltd Zuoyixiang,
Baise City, Guangxi Zhuang, CN. (C25C 3/08, OS
10 2011 001 834, AT: 06.04.2011)
Verwendung eines latent reaktiven Klebefilms
zur Verklebung von eloxiertem Aluminium mit
Kunststoff. tesa SE, 20253 Hamburg, DE. (C09J
175/00, OS 10 2012 203 249, AT: 01.03.2012)
Aluminium-Verglasungsrahmen aus Stangenpressprofil,
bei dem sich aus einem Profil
für eine Wanddicke (z. B. 100 mm) fünf verschiedene
Varianten herstellen lassen und bei
dem die Spiegelabdeckungen beidseitig geklipst
werden. Scheufler, Henry, 59494 Soest,
DE. (E06B 3/16, OS 10 2013 001 290, AT:
11.01.2013)
Aluminium-Lärmschutzwandsystem für Verkehrswege
mit neuartiger Schalldämmung für
bestimmte Frequenzen. Lublow, Felix, 59199
Bönen, DE; Wernal Profil Technik GmbH, 59457
Werl, DE. (E01F 8/00, GM 20 2006 001 472, AT:
30.01.2006)
Aluminium-Gleitlagerlegierung. Deutsches Zentrum
für Luft- und Raumfahrt e.V., 51147 Köln,
DE; TU Clausthal, 38678 Clausthal-Zellerfeld,
DE. (C22C 21/00, OS 50 2005 006 241, EP
1888798, WO 2006/131129, AT: 07.06.2005,
EP-AT: 07.06.2005, WO-AT: 07.06.2005)
Heißversiegelungsmasse für Aluminium- und
Polyethylenterephthalatfolien gegen Polypropylen-Polyvinylchlorid-
und Polystyrolbehälter.
Evonik Röhm GmbH, 64293 Darmstadt, DE.
(C08L 51/08, EP 2 497 799, AT: 19.12.2006, EP-
AT: 19.12.2006)
Mit Harz beschichteter, nahtloser Dosenkörper
aus Aluminium. Toyo Seikan Kaisha, Ltd.,
Tokio, JP. (B65D 1/12, PS 60 2004 039 037, EP
1640277, WO 2004/113181, AT: 22.06.2004,
EP-AT: 22.06.2004, WO-AT: 22.06.2004)
Katalysator, der Silizium, Magnesium, Aluminium
und Nanopartikel aus Nickel enthält und
dessen Verwendung in einer Methode zur
Zersetzung von C2-Kohlenwasserstoffen. Toda
Kogyo Corporation, Otake, Hiroshima, JP. (B01J
23/78, PS 60 2006 032 130, EP 1759764, AT:
09.08.2006, EP-AT: 09.08.2006)
Verfahren und Vorrichtung und Ablösung von
Anodenbasiskappen, insb. für zur Herstellung
von Aluminium durch Elektrolyse verwendete
Anoden. ECL, Ronchin, FR. (C25C 3/12, PS 60
2008 017 928, EP 2212450, WO 2009/098367,
AT: 07.11.2008, EP-AT: 07.11.2008, WO-AT:
07.11.2008)
Herstellung von kohlenstoffarmem Aluminium
durch carbothermische Reduktion in einem
einzigen Reaktor mit Rückführung des behandelten
Reaktorgases. Alcoa Inc., Pittsburgh,
Pa., US. (C22B 21/02, PS 60 2008 018 195, EP
2121995, WO 2008/100650, AT: 04.01.2008,
EP-AT: 04.01.2008, WO-AT: 04.01.2008)
Aluminiumlegierung mit hoher Beständigkeit
gegen Korrosion durch Meerwasser und Lamellen-Wärmetauscher.
Kabushiki Kaisha Kobe
Seiko Sho (Kobe Steel, Ltd.), Kobe-shi, Hyogo, JP.
(C23C 28/00, EP 1 927 676, AT: 04.10.2007, EP-
AT: 04.10.2007)
Aluminiumlegierung mit hoher Festigkeit bei
erhöhter Temperatur. Aleris Rolled Products
Germany GmbH, 56070 Koblenz, DE. (B32B 15/
01, EP 2 129 520, WO 2008/110270, AT: 28.02.
2008, EP-AT: 28.02.2008, WO-AT: 28.02.2008)
Verbesserte 2xxx-Aluminiumlegierungen und
Verfahren zu ihrer Herstellung. Alcoa Inc.,
Pittsburgh, PA 15212-5858, US. (C22C 21/00,
EPA 2625302, WO 2012/044450, EP-AT: 05.10.
2011, WO-AT: 05.10.2011)
Verfahren zur Herstellung eines mit einem
Hohlraum versehenen Leichtmetallbauteils.
Martinrea Honsel Germany GmbH, 59872 Meschede,
DE. (B22D 18/02, EPA 2617502, EP-AT:
14.01.2013, WO-AT: 14.01.2013)
Leichtmetall-Fahrzeugaufhängungselement.
Suzuki Motor Corp., Hamamatsu-shi, Shizuokaken,
JP. (B62D 21/11, OS 10 2013 004 804, AT:
13.03.2013)
Verbund von Zylinderlaufbuchsen aus Leichtmetalllegierung,
Verfahren zum Herstellen
eines Verbundes und Verfahren zum Eingießen
eines Verbundes. Peak Werkstoff GmbH, 42553
Velbert, DE. (B22D 15/02, PS 102 35 910, AT:
06.08.2002)
Lotpulver. Erbslöh Aluminium GmbH, 42553 Velbert,
DE. (B23K 1/00, OS 10 2012 006 121, AT:
26.03.2012)
Fortsetzung in ALUMINIUM 12/2013
ALUMINIUM · 11/2013 67

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
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
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 refractory products
Feuerfesttechnik
1.17 Protective Clothing
Schutzkleidung
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
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
• Anode Technology &
Mixing Equipment
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
• Rodding shop
www.brochot.fr
68 ALUMINIUM · 11/2013

suppliers directory
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
www.alu-web.de
1.5 Casthouse (foundry)
Gießerei
Furnaces
casting machines
transport crucibles
info@bartz-maschinenbau.de
www.bartz-maschinenbau.de
MoBiLe
eQuiPMent
Phone: +31.315.683941
info@hencon.com · www.hencon.com
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
inotHerM induStrieoFenund
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
see Equipment and accessories 3.1
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
E-Mail: interstop@stopinc.ch
Internet: www.stopinc.ch
• 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
Bartz GmbH
www.brochot.fr
see Casthous (foundry) 1.5
www.alu-web.de
• Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
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
• 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
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
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
Bartz GmbH
see Casthous (foundry) 1.5
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Treatment of casthouse
off gases
Behandlung der Gießereiabgase
Gautschi
engineering GmbH
see Casting equipment 3.1
1.6 Casting machines
Gießmaschinen
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
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
GAPcast
tM : the Swiss casting solution
see Casting machines and equipment 4.7
www.mechatherm.com
see Smelting technology 1.5
ALUMINIUM · 11/2013 69

lieferverzeichnis
• Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Bartz GmbH
see Casthous (foundry) 1.5
Gautschi
engineering GmbH
see Casting equipment 3.1
• Rolling and extrusion ingot
and T-bars
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Horizontal continuous casting
Horizontales Stranggießen
Gautschi
engineering GmbH
see Casting equipment 3.1
sermas@sermas.com
• Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• 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
1.9 Potroom
Elektrolysehalle
MoBiLe
eQuiPMent
Phone: +31.315.683941
info@hencon.com · www.hencon.com
t.t. tomorrow technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
E-Mail: gmagarotto@tomorrowtechnology.it
Contact: Giovanni Magarotto
• 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
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Scales / Waagen
Gautschi
engineering GmbH
see Casting equipment 3.1
1.8 Electrolysis cell (pot)
Elektrolyseofen
• Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: info.cc-mh@coperion.com
• Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios environnement
www.fivesgroup.com
• Pot ramming Machine
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Sawing / Sägen
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• 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
www.brochot.fr
• Tapping vehicles/Schöpffahrzeuge
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
1.12 Cathode repair shop
Kathodenreparatur-
Werkstatt
• Cathode Sealing Bench
Eingießen von Kathodenbarren
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
70 ALUMINIUM · 11/2013

suppliers directory
1.14 Aluminium Alloys
Aluminiumlegierungen
SMS Siemag AG
see rolling mill technology 3.0
• Billet heating furnaces
Öfen zur Bolzenerwärmung
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
1.15 Storage and transport
Lager und Transport
www.brochot.fr
1.16 Refractory Products
Feuerfesttechnik
refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
1.17 Protective Clothing
Schutzkleidung
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: sales@ias-induction.com
Internet: www.ias-induction.com
see Casthouse (foundry) 1.5
2.2 Extrusion equipment
Strangpresseinrichtungen
see Coil transport systems 3.4
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
2.4 Heat treatment
wärmebehandlung
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
www.charnaud.co.za +27 (0)11794 6040
www.charnaud.eu +44 (0)1133 507651
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
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
• 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
2.3 Section handling
Profilhandling
cti Systems S.A.
Z.I. Eselborn-Lentzweiler
12, op der Sang | L- 9779 Lentzweiler
Tel. +352 2685 2000 | Fax +352 2685 3000
cti@ctisystems.com | www.ctisystems.com
ALUMINIUM · 11/2013 71

lieferverzeichnis
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
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
mfw-maschinenbau.com
• Skip Handling, Spacer
• Kettenförderer
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
see Coil transport systems 3.4
see Section handling 2.3
• Section transport equipment
Profiltransporteinrichtungen
see Section handling 2.3
2.4 Heat treatment
Wärmebehandlung
mfw-maschinenbau.com
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
see Coil transport systems 3.4
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
• Section saws
Profilsägen
see Coil transport systems 3.4
see Section handling 2.3
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
• Stackers / Destackers
Stapler / Entstapler
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
mfw-maschinenbau.com
• Kurzlängensäge automatisiert
• Section store equipment
Profil-Lagereinrichtungen
www.ctisystems.com
see Section handling 2.3
could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
e-Mail: anzeigen@giesel.de
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
www.alu-web.de
www.mechatherm.com
see Smelting technology 1.5
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
inotHerM induStrieoFenund
WÄrMetecHnik GMBH
see Casthouse (foundry) 1.5
72 ALUMINIUM · 11/2013

suppliers directory
ernSt reinHArdt GMBH
Güterbahnhofstrasse 1
D-78048 Villingen-Schwenningen
Tel. +49 (0) 7721 8441-0, Fax -44
E-Mail: info@ernstreinhardt.de
Internet: www.ernst-reinhardt.com
• Homogenising furnaces
Homogenisieröfen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
2.10 Machining of sections
Profilbearbeitung
• Billet saw
Bolzensägen
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
www.alu-web.de
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
• Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
see 2.1 Billet heating furnaces
• Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
see Extrusion billet preparation 2.1
see Heat treatment furnaces 2.4
see Casthouse (foundry) 1.5
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 Casthouse (foundry) 1.5
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
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
3.7 Thin strip / foil rolling plant
3.0 Rolling mill technology
Walzwerktechnik
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
mfw-maschinenbau.com
• Strahlanlagen
see Cold rolling units / complete plants 3.6
www.alu-web.de
Siemens plc, Metals technologies
Sheffield Business Park, Europa Link
Sheffield S9 1Xu
Phone: +44 1709 726500
Fax:+44 1142 611719
aluminiummill.metals@siemens.com
ALUMINIUM · 11/2013 73

lieferverzeichnis
• Melting and holding furnaces
Schmelz- und Warmhalteöfen
• Annealing furnaces
Glühöfen
Bartz GmbH
see Casthous (foundry) 1.5
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
ein eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 + MwSt.
Weitere informationen unter
tel. +49 (0) 821 / 31 98 80 - 34
3.1 Casting equipment
Gießanlagen
www.mechatherm.com
see Smelting technology 1.5
• Electromagnetic Stirrer
Elektromagnetische Rührer
Solios thermal uk
www.fivesgroup.com
• Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
engineering GmbH
see Casting equipment 3.1
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
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
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
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
see Heat treatment 2.4
www.alu-web.de
• Bar heating furnaces
Barrenanwärmanlagen
eBner industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
engineering GmbH
see Casting equipment 3.1
• 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
• Roller tracks
Rollengänge
see Heat treatment 2.4
Gautschi
engineering GmbH
see Casting equipment 3.1
74 ALUMINIUM · 11/2013

suppliers directory
3.4 Hot rolling equipment
Warmwalzanlagen
• Rolling mill modernisation
Walzwerksmodernisierung
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
see Cold rolling units / complete plants 3.6
www.siemens.vai.com
see rolling mill technology 3.0
• Coil transport systems
Bundtransportsysteme
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
www.siemens.vai.com
see rolling mill technology 3.0
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
AndritZ Sundwig GmbH
Stephanopeler Str. 22, D-58675 Hemer
Telefon: +49 (0) 2372 54-0, Fax -200
E-mail: sundwig_welcome@andritz.com
Internet: www.andritz.com
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
www.ctisystems.com
see Section handling 2.3
SMS LoGiStikSYSteMe GMBH
obere Industriestraße 8
D-57250 netphen
Telefon: +49 2738 21-0
Telefax: +49 2738 21-1002
E-Mail: info@sms-logistics.com
www.sms-logistiksysteme.com
see Section handling 2.3
• Drive systems / Antriebe
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
• Spools / Haspel
SMS Siemag AG
see rolling mill technology 3.0
• Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
www.siemens.vai.com
see rolling mill technology 3.0
• Coil annealing furnaces
Bundglühöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
schwartz GmbH
see Equipment and accessories 3.1
see Heat treatment 2.4
www.alu-web.de
• Coil transport systems
Bundtransportsysteme
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
www.siemens.vai.com
see rolling mill technology 3.0
SMS Siemag AG
see rolling mill technology 3.0
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
see Coil transport systems 3.4
ALUMINIUM · 11/2013 75

lieferverzeichnis
see Section handling 2.3
• Rolling mill modernization
Walzwerkmodernisierung
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
• Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
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
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
www.siemens.vai.com
see rolling mill technology 3.0
SMS Siemag AG
see rolling mill technology 3.0
• Drive systems / Antriebe
SMS Siemag AG
see rolling mill technology 3.0
• Heating furnaces / Anwärmöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
• Process optimisation systems
Prozessoptimierungssysteme
Gautschi
engineering GmbH
see Casting equipment 3.1
• Process simulation
Prozesssimulation
Gautschi
engineering GmbH
see Casting equipment 3.1
SMS Siemag AG
see rolling mill technology 3.0
• Roll exchange equipment
Walzenwechseleinrichtungen
SMS Siemag AG
see rolling mill technology 3.0
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
Hier könnte Ihr
Bezugs-
quellen-
Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• 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
www.siemens.vai.com
see rolling mill technology 3.0
• 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
• Heating furnaces
Anwärmöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
inotHerM induStrieoFenund
WÄrMetecHnik GMBH
see Casthouse (foundry) 1.5
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
schwartz GmbH
see Heat treatment 2.4
• Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
Mino S.p.A.
Via Torino, 1 – San Michele
15122 ALESSAnDrIA – ITALy
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
76 ALUMINIUM · 11/2013

suppliers directory
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
• 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
SMS Siemag AG
see rolling mill technology 3.0
• Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
• 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
• Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
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
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
• 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
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
3.11 Coolant / lubricant
preparation
Kühl-/Schmiermittel-
Aufbereitung
wagstaff, Inc.
see Casting machines 1.6
• Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
see Cold rolling units / complete plants 3.6
• Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
see rolling mill technology 3.0
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
ein eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 + MwSt.
Weitere informationen unter
tel. +49 (0) 821 / 31 98 80 - 34
• 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
ALUMINIUM · 11/2013 77

lieferverzeichnis
• Rolling oil rectification units
Walzölrektifikationsanlagen
3.16 Coil storage systems
Bundlagersysteme
• Coil & Colour Coating Lines
Bandlackierlinien
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
3.12 Air extraction systems
Abluft-Systeme
see Cold rolling units / complete plants 3.6
• Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
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
see Coil transport systems 3.4
SMS Siemag AG
see rolling mill technology 3.0
see Section handling 2.3
3.17 Strip Processing Lines
Bandprozesslinien
see Cold rolling equipment 3.6
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
Bronx international Pty Ltd
Email: sales@bronx.com.au
Internet: www.bronxintl.com
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
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
see Coil transport systems 3.4
SMS Siemag AG
see rolling mill technology 3.0
redex
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
E-mail: info@redex-group.com
Internet: www.tension-leveling.com
www.alu-web.de
• Anodizing Lines
Anodisier-Linien
SMS Siemag AG
see rolling mill technology 3.0
3.18 Production
Management systems
Produktions Management
Systeme
PSi Metals non Ferrous GmbH
Software Excellence in Metals
Carlo-Schmid-Str. 12, D-52146 würselen
Tel.: +49 (0) 2405 4135-0
info@psimetals.de, www.psimetals.com
see Coil transport systems 3.4
78 ALUMINIUM · 11/2013

suppliers directory
4 Foundry
Gießerei
4.1 work protection and ergonomics
Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology
Feuerfesttechnik
4.3 Conveyor and storage technology
Förder- und Lagertechnik
4.4 Mould and core production
Form- und Kernherstellung
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.2 Heat-resistent technology
Feuerfesttechnik
• Refractories / Feuerfeststoffe
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik und Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
regelungstechnik
4.17 Environment protection
and disposal
umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
Promat GmbH High Performance insulation
Scheifenkamp 16, D-40878 ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
verkauf3@promat.de, www.promat.de
H+H HerrMAnn + HieBer GMBH
rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
see Coil transport systems 3.4
see Section handling 2.3
4.5 Mold accessories and
accessory materials
Formzubehör, Hilfmittel
• Fluxes
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
4.6 Foundry equipment
Gießereianlagen
Hencon MoBiLe eQuiPMent
see section Casthouse 1.5
www.mechatherm.com
see Smelting technology 1.5
• Casting machines
Gießmaschinen
Via Brallo, 2 – 27010 Siziano (PV), Italy
Tel: +39 0382 6671413
E-mail: sales_dept@erediscabini.com
Internet: www.erediscabini.com
refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
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.alu-web.de
www.alu-web.de
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
Paul Hedfeld GmbH
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: verkauf@hedfeld.com
Internet: www.hedfeld.com
see Equipment and accessories 3.1
• Heat treatment furnaces
Wärmebehandlungsöfen
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
see Casthouse (foundry) 1.5
ALUMINIUM · 11/2013 79

lieferverzeichnis
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPcast
tM : the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: 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
wagstaff, Inc.
see Casting machines 1.6
Hier könnte Ihr
Bezugs-
quellen-
Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• 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
ein eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 + MwSt.
Weitere informationen unter
tel. +49 (0) 821 / 31 98 80 - 34
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
4.13 Melt operations
Schmelzbetrieb
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
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.
• Heat treatment furnaces
Wärmebehandlungsanlagen
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
see Equipment and accessories 3.1
• Holding furnaces
Warmhalteöfen
Bartz GmbH
see Casthous (foundry) 1.5
Gautschi
engineering GmbH
see Casting equipment 3.1
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
see Equipment and accessories 3.1
could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
e-Mail: anzeigen@giesel.de
• Melting furnaces
Schmelzöfen
Bartz GmbH
see Casthous (foundry) 1.5
80 ALUMINIUM · 11/2013

suppliers directory
Gautschi
engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
inSertec-inGenierÍA Y SerVicioS tÉcnicoS, S.A
see Heat treatment 2.4
see Equipment and accessories 3.1
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
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
ein eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 + MwSt.
Weitere informationen unter
tel. +49 (0) 821 / 31 98 80 - 34
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
could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
e-Mail: anzeigen@giesel.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
• 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
ALUMINIUM · 11/2013 81

VOrSCHaU / PrEVIEW
IM NÄCHSTEN HEFT
Special: Die europäische Gießereibranche
Wir berichten im Vorfeld der Euroguss-Messe im Januar
2014 über Unternehmen aus und Branchenentwicklungen
in der Gießereibranche:
• Europäische Gießereiausrüster behaupten sich in
schwierigem Umfeld
• Strategien für die Druckgießereien von morgen
• DGS Druckguss Systeme AG – Entwicklungspartner der
Automobilindustrie für Strukturteile aus Leichtmetall
• Behandlung von trennmittelhaltigen Abwässern
Weitere Themen
• Die globale Aluminiumindustrie – aktuelle Lage und
Marktaussichten
• Betriebspunktmessung an Heißgasventilatoren in
Industrieöfen – ein Praxisbeispiel
IN THE NEXT ISSUE
Special: The European foundry industry
In the run-up to the Euroguss trade fair, we will report on
companies and equipment partners of the foundry industry
and sector develoments:
• European suppliers of casting machines hold their
ground in difficult environment
• DGS Druckguss Systeme AG – Development partner of
the car industry for light-metal structural parts
• The solution for wastewater containing mould release
agents from aluminium die casting
Other topics
• The aluminium industry – current situation and market
prospects
• Development funding supports US scrap processing sector
• Granco Clark: Extrusion equipment systems maximise
performance and profits
Erscheinungstermin: 05. Dezember 2013
Anzeigenschluss: 21. November 2013
Redaktionsschluss: 11. November 2013
Date of publication: 05 December 2013
Advertisement deadline: 21 November 2013
Editorial deadline: 11 November 2013
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
Postbank / postal cheque account Hannover, BLZ / routing
code: 25010030; Kto.-Nr. / account no. 90898-306,
Bankkonto/bank account Commerzbank AG, BLZ/routing
code: 25040066, Kto.-Nr./account no. 1500222
Geschäftsleitung / Managing Director
Klaus Krause
Redaktion / Editorial office
Dipl.-Vw. Volker Karow
Chefredakteur, Editor in Chief
Franz-Meyers-Str. 16, 53340 Meckenheim
Tel. +49(0)2225 8359643, Fax +49(0)2225 18458
vkarow@online.de
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
Objektleitung / General Manager
Material Publication
Dennis Roß
Tel. +49(0)821 319880-34, d.ross@giesel.de
Anzeigenpreise / Advertisement rates
Preisliste Nr. 53 vom 1. Oktober 2012
Price list No. 53 from 1 Oct. 2012
Druckunterlagen / Print documents
anzeigendaten-ajo@schluetersche.de
Tel. +49(0)511 8550-2522, Fax +49(0)511 8550-2401
Vertrieb / Distribution
Tel. +49(0)511 8550-2638, Fax +49(0)511 7304-233
vertrieb@giesel.de
Jahresbezugspreis
EUR 297,- (Inland inkl. 7% MwSt. und Versand kosten).
Europa EUR 297,- inkl. Versandkosten. Einzelausgabe EUR
29,80. Übersee US$ 393,– inkl. Normalpost; Luftpost zzgl.
US$ 84,–. Einzelaus-gabe US$ 39,30. Preise für Studenten
auf Anfrage. ALUMINIUM erscheint zehnmal pro Jahr. Kündigungen
jeweils sechs Wochen zum Ende der Bezugszeit.
Subscription rates
EUR 297.00 p.a. (domestic incl. V.A.T.) plus postage. Europe
EUR 297.00 incl. surface mail. Single copy EUR 29.80. Out side
Europe US$ 393.00 incl. surface mail, air mail plus US$ 84.00.
Single copy US$ 39.30. ALUMINIUM is published monthly
(10 issues a year). Cancellations six weeks prior to the end
of a year.
Die Zeitschrift und alle in ihr enthaltenen Beiträge und
Abbildungen sind urheberrechtlich geschützt. Jede Verwertung
außerhalb der en gen Grenzen des Urheberrechtsgesetzes
ist ohne Zustimmung des Verlages unzulässig
und strafbar. Das gilt insbesondere für Ver vielfältigungen,
Übersetzungen, Mikroverfilmungen und die Einspeicherung
und Bearbeitung in elektronischen Systemen. Der
Ver lag übernimmt keine Gewähr für die Richtigkeit der in
diesem Heft mitgeteilten Informationen und haftet nicht für
abgeleitete Folgen. Haftung bei Leistungsminderung durch
höhere Gewalt oder andere vom Verlag nicht verschuldete
Umstände (z. B. Streik) ist ausgeschlossen.
This jour nal and all con tri bu tions con tained there in are protect
ed by copy right. Any util iza tion out side the strict lim its
of copy right leg is la tion with out the ex press con sent of the
pub lish er ist pro hib it ed and ac tion able at law. This ap plies
in par ticular to re pro duc tion, trans la tions, mi cro film ing and
stor age or pro cess ing in elec tron ic systems. The pub lishe r
of fers no guar an tee that the in for ma tion in this vol ume is
ac cu rate and ac cepts no li abil ity for con se quenc es de riv ing
there from. No li abil ity what soev er is ac cept ed for per fomance
lag caused by force ma jeure or by cir cum stance s
be yond the publisher’s con trol (e.g. in dus tri al ac tion).
ISSN: 0002-6689
© Giesel Verlag GmbH
Verlagsrepräsentanz / Representatives
Giesel Verlag GmbH
Büro Augsburg: Gögginger Straße 105a, 86199 Augsburg
Dennis Roß Tel. +49(0)821 319880-34 d.ross@giesel.de
Claus Mayer Tel. +49(0)821 319880-37 c.mayer@giesel.de
Stephan Knauer Tel. +49(0)821 319880-19 s.knauer@giesel.de
Fax +49(0)821 319880-80
Austria, Scandinavia, Denmark,
Netherlands, Belgium, Luxembourg
Giesel Verlag GmbH
Büro Augsburg: Gögginger Straße 105a, 86199 Augsburg
Dennis Roß Tel. +49(0)821 319880-34 d.ross@giesel.de
Claus Mayer Tel. +49(0)821 319880-37 c.mayer@giesel.de
Stephan Knauer Tel. +49(0)821 319880-19 s.knauer@giesel.de
Fax +49(0)821 319880-80
Switzerland
JORDI PUBLIPRESS, Postfach 154, CH-3427 Utzenstorf
Tel. +41(0)32 6663090, Fax +41(0)32 6663099
info@jordipublipress.ch, www.jordipublipress.ch
Italy
MEDIAPOINT & COMMUNICATIONS SRL
Corte Lambruschini – Corso Buenos Aires, 8
V o piano – Interno 7, I-16129 Genova
Tel. +39(0)10 5704948, Fax +39(0)10 5530088
info@mediapointsrl.it, www.mediapointsrl.it
United Kingdom, USA, Canada, Africa,
GCC countries etc.
Marketing Xpertise Rieth, Dipl.-Ing. Bernhard Rieth
Strümper Berg 10, D-40670 Meerbusch
Tel. +49(0)2159 962643, Fax +49(0)2159 962644
marketing.xpertise@t-online.de
France
DEF & Communication, Romain Linguanotto
48 boulevard Jean Jaurès, F-92110 Clichy
Tel. +33(0)147307181, Fax +33(0)147300189
rlinguanotto@defcommunication.com
Angeschlossen der Informationsgemeinschaft zur
Feststellung der Verbreitung von Werbeträgern (IVW)
Druck / Printing house
Gutenberg Beuys Feindruckerei GmbH
Hans-Böckler-Straße 52, 30851 Langenhagen
Der ALUMINIUM-Branchentreff des Giesel Verlages:
www.alu-web.de
82 ALUMINIUM · 11/2013 5/2012

It‘s a pure waste of time
... if you make do with anything less!
All the very latest information in a single publication,
10 times a year, excellently researched,
direct from the source!
Test it now!
YES, I would like to receive
regular information on
the latest trends and
technologies!
Please send me a sample
copy at no obligation.
I wish to subscribe to
INTERNATIONAL ALUMINIUM
JOURNAL
The subscription price is
EUR 297.00 a year incl. p&p
and VAT (Outside Europe:
US$ 393.00).
INTERNATIONAL ALUMINIUM JOURNAL is
published monthly with double editions in
January/February and in July/August. Subscriptions
are initially valid for a year.
Company
Name, first name
Street, No.
Postcode, town
Tel.
Fax
Email
Q The subscription price is to be paid by
credit card:
Q VISA
Q American Express
Q Euro-/Mastercard
Number
Cardholder
Valid until
Q The price is to be debited from our
account (only possible within Germany)
Bank
Bank code
Account no
Q The price will be remitted on receipt
of the invoice
Date
Signature
Subscription service | vertrieb@giesel.de | Fax +49 (0)511 7304-233

Trust...
Solid competence for the aluminum industry
Being able to trust in the expertise and performance of
every team member, is the foundation for success. To our
customers around the world this means being able to count
on a comprehensive offering in the area of aluminum production.
From thermal pre-treatment to shaping and refining, we
always meet the constantly rising challenges of the market.
Whether in new plant construction or revamp projects, our
solid process know-how encompasses the complete production
cycle, including the integration of the latest electrical
engineering and automation solutions.
Confidence through performance – SMS Siemag.
SMS SIEMAG AG
Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: communications@sms-siemag.com
40237 Düsseldorf, Germany Fax: +49 211 881-4902 Internet: www.sms-siemag.com