sPeCIAL ArABAL - ALUMINIUM-Nachrichten – ALU-WEB.DE

Official media partner of 17 th Arabal Conference
Special:
The aluminium industry
in the Gulf / Arabal 2013
Interview with Emal CEO
Saeed Fadhel Al Mazrooei
Kizad aluminium
cluster taking shape
Best technology for the
rolling industry in the Gulf
© Emal
EPCM – a vital activity in
the world of aluminium
Volume 89 · September 2013
International Journal for Industry, Research and Application9

Air Cooled Open Mould Ingot Caster – Hertwich OMC series III
State-of-the-art open mould ingot casting
Leading technology in the aluminum casthouse
There are many benefits in one-stop-shopping of industrial
goods. At Hertwich Engineering we provide customer
oriented service throughout the project duration and
service life of equipment. We design and build plants to
meet both, our own stringent standards and individual
customers speci fications. Based on many years of experience,
we cover the full range of equipment in a modern
aluminum casthouse.
Major benefits
Hertwich Engineering is well-known for leading edge
technology. Our discerning customers deserve to get the
best value for money. Commitment to innovation, solid
engineering and own R&D are instrumental for staying
ahead with continuous improvements and new products.
Advantages of primary cooling by air –
Hertwich OMC series III
Safety, no water explosion hazard
Optimized pouring trough for minimum melt turbulence,
no oxide formation, no dedrossing required
uniform shrinkage during solidification
mould temperature adjustable prior metal pouring
enhanced air cooling for optimum solidification (eutectic alloys)
air cooled moulds are not subject to temperature shock
no exposure to water - almost unlimited
service life of moulds
less maintenance
Downstream equipment includes automated stacking, marking,
strapping, colour coding, weighing and labelling.
HERTWICH ENGINEERING GMBH
Weinbergerstrasse 6 Phone: +43 7722 806-0 E-mail: info@hertwich.com
5280 Braunau, Austria Fax: +43 7722 806-122 Internet: www.hertwich.com

EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Die Aluminiumwelt
trifft sich in Abu Dhabi
Aluminium world to
meet in Abu Dhabi
Zum zweiten Mal in diesem Jahr blicken wir
in unserem Special auf die Golfregion. Nach
der Aluminium Middle East 2013 im April in
Dubai steht im November ein zweites Großereignis
vor der Tür, dann in Abu Dhabi: die
Arabal Conference 2013, dieses Jahr ausgerichtet
von Emirates Aluminium. Der Veranstaltungsort
ist vorausschauend gewählt: In
Abu Dhabi entsteht mit Kizad ein riesiges Industriegebiet,
das sowohl heimische wie ausländische
Investoren und unterschiedlichste
Branchen anziehen will. Dieses Industrieprojekt
ist weit sichtbarer Ausdruck dessen,
dass sich die Golf-Staaten im globalen Wirtschaftsgeschehen
längst nicht mehr nur auf
Öl und Gas exportierende Länder reduzieren
lassen. Stattdessen sind sie auf dem Weg zu
wirtschaftlich diversifizierten Gesellschaften,
die ihrer Bevölkerung neue Entwicklungsperspektiven
eröffnen.
Die dreitägige Veranstaltung steht im Zeichen
jüngster und künftiger Entwicklungen
und Projekte aus dem Upstream- und Downstream-Sektor
der Aluminiumindustrie am
Golf. Darüber hinaus wird der Bogen zu den
globalen Marktfragen und wirtschaftlichen
Herausforderungen der Branche gespannt –
bis hin zu Aspekten des LME-Warehousing,
das in jüngster Zeit durch die Ereignisse um
Goldman Sachs besondere Aktualität erfährt.
Details des Programms können in dieser Ausgabe
nachgelesen werden (S. 32).
Dass die Konferenz von Emal ausgerichtet
wird, versteht sich fast von selbst. In Abu
Dhabi ansässig spielt Emal eine zentrale Rolle
beim Aufbau des Aluminiumclusters in Kizad.
Obendrein entsteht derzeit Emals dritte
Ofenlinie, mit der das Unternehmen seine
Hüttenproduktion auf 1,3 Mio. Tonnen fast
verdoppeln wird. Den Konferenzteilnehmern
bietet sich Gelegenheit zu einer Besichtigungstour,
die einen bleibenden Eindruck von diesem
Produktionsstandort hinterlassen wird.
ALUMINIUM sprach jüngst mit Emal President
und CEO Saeed Fadhel Al Mazrooei
über die Entwicklung des Unternehmens, seine
Marktstellung, die Erwartungen an die Arabal-Konferenz
und die Integration von Dubal
und Emal zu Emirates Global Aluminium.
Auch für die Ausrüster der Aluminiumindustrie
sind die Golf-Staaten von wachsender
Bedeutung geworden. Das betraf in den
letzten Jahren zum einen die Anbieter von
Maschinen und Anlagen für Anodenfabriken,
Hütten und Gießereien, zum anderen die
Ausrüster für Strangpresswerke. Inzwischen
sind mit Oman Aluminium Rolling Co. und
dem Ma’aden-Alcoa-Walzkomplex zwei Flagschiffprojekte
für Walzprodukte hinzugekommen,
die kurz vor Fertigstellung stehen.
For the second time this year our Special
is looking at the Gulf region. Following Aluminium
Middle East 2013 in Dubai, a second
major event is fast approaching and will take
place in November: the Arabal Conference
2013, this year hosted by Emirates Aluminium.
The venue has been chosen with foresight:
in Abu Dhabi a superlative industrial development
project – Kizad – is nascent which aims
to attract both domestic and foreign investors
and the most varied industry sectors. This industrial
project is a highly visible demonstration
that nowadays the Gulf States are much
more than oil and gas exporting countries. Instead,
they are on the way towards becoming
economically diversified societies which are
opening up new development prospects for
their population.
The three-day event will be taking place
against the background of recent and future
developments in the Gulf region. Naturally, the
focus is on regional projects in the upstream
and downstream sectors of the aluminium industry.
Moreover, an approach will be made
to global market questions and the economic
challenges faced by the industry – including
aspects related to LME warehousing which
has recently become particularly topical in the
light of events surrounding Goldman Sachs.
For details of the programme see page 32.
That the conference is being organised by
Emirates Aluminium is almost self-explanatory.
Located in Abu Dhabi, the company plays
a central role in building up the aluminium
cluster in Kizad. On top of everything else
Emal’s third potline is under construction,
with which the company will almost double
its aluminium output to 1.3 million tonnes.
Conference participants will be offered the
opportunity to be taken on a site tour which
will certainly leave them with a lasting impression
of this smelter complex. Recently ALU-
MINIUM had the opportunity to talk with the
president and CEO of Emal, Saeed Fadhel Al
Mazoorei – about the company’s development,
its market position, what is expected
from the Arabal Conference, and the merger
of Dubal and Emal into Emirates Global Aluminium
(see pp. 26-30).
For equipment suppliers to the aluminium
industry the Gulf countries have become increasingly
important. In recent years that has
concerned on the one hand suppliers of plant
and machinery for anode plants, smelters and
casthouses, and on the other hand suppliers
of extrusion plants. Meanwhile, with Oman
Aluminium Rolling Co. and the Ma’aden-
Alcoa rolling complex two flagship projects
for rolled products have been added, both of
them nearing completion.
ALUMINIUM · 9/2013 3

INHALT
EDITORIAL
Die Aluminiumwelt trifft sich in Abu Dhabi
Aluminium world to meet in Abu Dhabi ........................................... 3
AKTUELLES • NEWS IN BRIEF • EVENTS ................... 6-10
WIRTSCHAFT • ECONOMICS
26
Al-Preise / Produktionsdaten der deutschen Aluminiumindustrie .....12/14
Aluminium S.A. increases production, reduces costs ..........................16
Aluminium – The transportation material of the future ......................19
Primary aluminium industry during the first half of 2013, Part II ........ 20
ALUMINIUM INDUSTRY IN THE GULF • ARABAL 2013
Interview with Emal president and CEO, Saeed Fadhel Al
Mazrooei:“We can compete with any company in the world” ............ 26
17 th Arab International Aluminium Conference 2013 ......................... 32
Best technology for the aluminium rolling industry in the Gulf ........... 34
38
Kizad aluminium cluster taking shape ............................................ 38
EPCM – a vital activity in the world of aluminium ........................... 42
In Europe, Middle East and Africa contact: COMEXALE TEL +33-3-83-354649 FAX +33-3-83-355092 WWW.comexale.com
4 ALUMINIUM · 9/2013

CONTENTS
Bechtel keeps building history ...................................................... 46
Aluminium Bahrain – One of the largest and
most modern aluminium smelters in the world ................................ 48
Successful start-up of the fume treatment
centre at Ras Al Khair aluminium smelter ....................................... 50
High performance of ‘Eolios’ pitch fume
treatment system at Qatalum paste plant ....................................... 54
TECHNOLOGIE • TECHNOLOGY
Köllemann GmbH – market leader for petcoke preheaters .................56
42
Integration der Gattierungsrechnung macht Recycling
noch effizienter • Integrated charge and alloy
calculation makes recycling even more efficient .............................. 58
Turla targets equipment quality and
performance for customer success..................................................62
Belte AG – Spezialist für die Wärmebehandlung von
Aluminiumbauteilen:„Wir sind ständig bestrebt, Prozesse
weiterzuentwickeln“ • Belte AG – Specialist in the
heat treatment of aluminium components:“We constantly
strive to develop our processes further” ..........................................66
Infrared heat transfer for thin-walled aluminium automotive castings ....69
Euroguss 2014: „Anmeldestand der Vorveranstaltung
bereits erreicht“ • Euroguss 2014 :“Level of
applications for previous event already reached” ..............................71
Gießtechnisch verbunden: Hybride CFK-Aluminium-
Fügeverbindung für den Leichtbau ..................................................72
ACTech nimmt Stoßwellenanlage zur
Entkernung komplexer Gussteile in Betrieb .......................................72
Automated band saws for precise linear cuts ....................................73
Innovative Lösungen für das Strahlen von Gussprodukten
Innovative shot blasting solutions for foundries .................................74
ANWENDUNG • APPLICATION
Aluminiumtube feiert 100 Jahre Erfolgsgeschichte
Aluminium tube celebrates centenary .............................................76
Opel stellt neuen Vollalu-Dreizylinder auf IAA vor
Opel presents new all-aluminium 3-cylinder at IAA ...........................77
COMPANY NEWS WORLDWIDE..................................... 78-82
DOCUMENTATION
Patente .....................................................................................82
Impressum • Imprint ....................................................................98
Vorschau • Preview .....................................................................98
LIEFERVERZEICHNIS • SUPPLIERS DIRECTORY .............84
Inserenten dieser Ausgabe
List of advertisers
54
Aluminium Bahrain, Bahrain 41
Arabal Conference 2013, UAE 33
Aumund Fördertechnik GmbH, Germany 47
Brochot, France 43
Buss AG, Switzerland 57
Castool Tooling Systems, Canada 4
De Winter Engineering, The Netherlands 75
Didion International Inc., USA 21
Dubal Aluminium, UAE 100
Emirates Aluminium UAE 13
Eredi Scabini Srl, Italy 51
Fata Hunter SpA, Italy 29
Fives Solios, France 31
Gautschi Engineering GmbH, Switzerland 35
Hertwich Engineering GmbH, Austria 2
IMS Messsysteme GmbH, Germany 7
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany 19 , 75
Italtecno, Italy 17
IUL – TU Dortmund, Germany 99
Kizad, Abu Dhabi 27
Maka Systems GmbH, Germany 25
Mino SpA, Italy 15
Precimeter Control AB, Sweden 37
Refratechnik Steel GmbH, Germany 39
Riedhammer GmbH, Germany 45
Rösler Oberflächentechnik GmbH, Germany 71
Siemens Plc, UK 11
Wagstaff Inc., USA 23
Yxlon International, Germany 9
ALUMINIUM · 9/2013 5

AKTUELLES
Amag voll ausgelastet, Ergebnis schwächer
Luftaufnahme vom Amag-Standort in Ranshofen, Österreich
Die Amag-Gruppe war im ersten Halbjahr
2013 in den drei Segmenten Metall, Gießen
und Walzen voll ausgelastet. Die Auftragslage
entwickelte sich im zweiten Quartal trotz
eines schwierigeren Konjunkturumfeldes zufriedenstellend.
Die gesamte Absatzmenge
konnte in den ersten sechs Monaten dieses
Jahres auf 181.900 Tonnen (+1%) gesteigert
werden, wobei der Zuwachs im Segment Walzen
(+4%) die Rückgänge in den Segmenten
Gießen und Metall (-2% bzw. -1%) ausglich.
Gegenüber dem Vorjahresquartal blieb die
Absatzmenge mit 93.700 Tonnen annähernd
stabil.
Der Halbjahresumsatz 2013 ging gegenüber
dem Vorjahreszeitraum um fünf Prozent
auf 412,4 Mio. Euro zurück – vor allem bedingt
durch den um acht Prozent niedrigeren
© Amag
durchschnittlichen Aluminiumpreis. Das
Ergebnis vor Zinsen, Steuern und Abschreibungen
(Ebitda) verringerte sich um 9,4 Prozent
auf 65,4 Mio. Euro.
Amag konnte Anfang 2013 einen Großauftrag
von EADS gewinnen, der die Lieferung
von Aluplatten und -blechen für Struktur- und
Außenhautteile vorsieht. Das Auftragsvolumen
beträgt bis zu 100 Mio. Euro. Der Werksausbau,
mit dem die Produktionskapazität in
Ranshofen um 50 Prozent ausgeweitet wird,
liegt laut Unternehmen voll im Plan. Das neue
Walzwerk werde im zweiten Halbjahr 2014
in Betrieb gehen, so Vorstandschef Gerhard
Falch.
Amag geht für das dritte Quartal von weiterhin
voll ausgelasteten Kapazitäten aus.
Ende Juli lag der LME-Preis für Aluminium
bei 1.800 Dollar je Tonne. Auch bei diesem
niedrigen Preisniveau könne die Alouette-
Hütte in Kanada aufgrund ihrer sehr guten
Kostenposition „einen wesentlichen Ergebnisbeitrag
liefern“, so das Unternehmen. Aufgrund
des niedrigeren Aluminiumpreises und
hohen Margendrucks erwartet der Vorstand
ein niedrigeres Gruppenergebnis als im Vorjahr.
Das Ebitda werde in der Bandbreite von
116 bis 121 Mio. Euro liegen.
Deutsche Aluminiumindustrie wächst in Erzeugung und Verarbeitung
© ALUMINIUM
Die deutsche Aluminiumindustrie hat sich im
ersten Halbjahr 2013 gut behauptet. Die Produktion
konnte in vielen Bereichen deutlich
zulegen. Für das zweite Halbjahr erwartet die
Branche weiteres Mengenwachstum.
Die Erzeugung von Rohaluminium stieg
auf 549.081 Tonnen und damit um 3,3 Prozent
gegenüber dem Vorjahreszeitraum.
Die Menge teilt sich auf in 233.363 Tonnen
Die Produktion von Walzprodukten legte im ersten Halbjahr 2013 zu
Hüttenaluminium (+15,1%) und 315.718
Tonnen Recyclingaluminium (-4,1%). GDA-
Geschäftsführer Christian Wellner dazu: „Im
ersten Halbjahr 2013 hat die deutsche Hüttenaluminiumproduktion
den höchsten Wert
seit der Wirtschaftskrise 2008/09 erreicht.
Damit bleibt die Erzeugung von Aluminium
ein wichtiger Wertschöpfungsbestandteil der
Aluminiumindustrie in Deutschland.“
Die Erzeugung von
Aluminiumhalbzeug
– Walz- und Strangpressprodukte
sowie Drähte
und Schmiedeteile – betrug
1,266 Mio. Tonnen
(+3,2%).
Die Produktion von
Aluminiumguss – Sand-,
Kokillen- und Druckguss
– sank dagegen deutlich,
und zwar auf 403.412
Tonnen (-7,2%). Im Juni
wurden dagegen 76.075
Tonnen und damit so viel
wie im Vorjahresmonat produziert.
175.378 Tonnen (+0,5%) wurden in der
Weiterverarbeitung hergestellt. Sie gliedert
sich in die Segmente Folien und dünne Bänder
(+0,2%), Tuben, Aerosol- und sonstige Dosen
(+5,7%) sowie Metallpulver (+5,0%).
Das konjunkturelle Umfeld war im ersten
Halbjahr relativ schwach und durch eine hohe
Unsicherheit gekennzeichnet. Nach Ansicht
von Andreas Postler, Leiter Volkswirtschaft
und Statistik beim GDA, hat sich die deutsche
Aluminiumindustrie in diesem Umfeld
jedoch gut behauptet. „Unsere Industrie hat
ihre Wettbewerbsfähigkeit in den letzten Jahren
durch Modernisierungen und Restrukturierungen
deutlich gesteigert. So konnten unsere
Unternehmen im ersten Halbjahr 2013
– trotz einer rückläufigen Mengenkonjunktur
– in vielen Segmenten Marktanteile gewinnen.“
Postler erwartet eine Fortsetzung dieser
positiven Entwicklung: „Das konjunkturelle
Umfeld hellt sich wieder auf. Für das zweite
Halbjahr gehen wir von einer leicht anziehenden
Mengenkonjunktur aus.“
6 ALUMINIUM · 9/2013

NEWS IN BRIEF
Alufoil: production and
deliveries on the rise
Deliveries of aluminium foil products moved
ahead in Q2 2013, confirming that the recovery
in demand seen in 2012 continues. Overall
production for the year to date reached
419,800 tonnes, a rise of 2.5% compared with
the first half of 2012. Exports too maintained
momentum, increasing by 3.2% in Q2 2013,
helping first half sales outside the European
market to an impressive 6.6% rise.
Q2 results showed thinner gauges, used
largely for flexible packaging and household
foils, once again led the way with a rise of
2.3%. Thicker gauges, used typically for semirigid
containers and technical applications,
dropped back by just 1.8%, indicating recovery
is more uneven for these products. Total
deliveries were 210,400 tonnes, which is an
increase of 1.3% compared with Q2 2012.
Manfred Mertens, EAFA vice-president
and Roller Group chairman, commented:
“While the outlook is still somewhat uncertain
there are clear signs that the trend is upward,
although there may still be some negative
quarters in some areas, the ‘downs’ seem to
be smaller and the ‘ups’ larger.”
Alufoil Trophy 2014 –
a chance to ‘shine’
in aluminium foil!
The launch of the Alufoil Trophy 2014, organised
by the European Aluminium Foil Association
(EAFA), offers companies the chance to
enter and place the spotlight on their latest
innovations and technologies using alufoil, in
the most prestigious competition of its kind.
Five categories for entries provide ample
scope for all kinds of creativity and technological
developments – across the entire range of
industrial applications and covering the most
crucial challenges for alufoil and aluminium
closure manufacturers. The categories are:
Marketing & Design, Consumer Convenience,
Resource Efficiency, Product Preservation
and Technical Innovation. Commenting
on the launch of this year’s competition
Guido Aufdemkamp, director Communication
at EAFA, said: “The Alufoil Trophy 2014 is
a special opportunity for companies to bring
worldwide attention to their latest ideas and
products. We look forward to an exciting and
hotly contested competition.”
Entries will be accepted until 29 November
2013. More details on www.alufoil.org.
© EAFA
Improve your
product quality!
IMS measuring systems
are designed for online,
non-contact operation in
the measurements of:
• Thickness and
thickness profile
• Wedge and crown
• Flatness
• Width and position
of material
• Dimension and geometry
• Edge defects and holes
• Coat thickness and
coat profile
• Speed and length
• Force and strip tension
Competence in
aluminium measurement
Your measurement
task is our
specialisation!
IMS Messsysteme GmbH
Dieselstraße 55 | 42579 Heiligenhaus | Germany | phone: +49 2056 975-0, fax: -140
info@ims-gmbh.de | www.ims-gmbh.de
ALUMINIUM · 9/2013 7

AKTUELLES
Trimet präsentiert sich auf der IAA
Strukturbauteile für Pkw
Auf der Internationalen Automobil-Ausstellung
(IAA), die in diesem Jahr vom 12. bis
22. September in Frankfurt am Main stattfindet,
präsentiert sich die Trimet Aluminium
SE als leistungsstarker Partner der Automobilindustrie.
Der mittelständische Werkstoffspezialist
behauptet sich mit Produkten und
Dienstleistungen aus einer Hand als Systemlieferant
der Branche. Der steigende Bedarf
nach Strukturteilen erweist sich für Trimet als
Wachstumstreiber. Marktentscheidend sind
unter anderem die Speziallegierungen, die Trimet
im eigenen Forschungslabor entwickelt.
Trimet hat im vergangenen Jahrzehnt für
rund 200 Mio. Euro die beiden Produktionsstandorte
in Harzgerode und Sömmerda ausgebaut,
um das Produktportfolio zu erweitern
und den wachsenden Kundenstamm aus der
© Trimet
Automobilindustrie zu bedienen. Zu den
Schwerpunkten im Automotive-Geschäft zählen
Getriebe- und Kupplungsgehäuse für Direktschaltgetriebe.
Zudem ist Trimet seit 2009
Alleinlieferant von Fahrwerksteilen für einen
namhaften deutschen Automobilhersteller.
Die im Kokillenguss hergestellten Fahrwerksteile
werden in Deutschlands modernster
Schwerkraftkokillenguss-Anlage am Standort
Harzgerode produziert.
Als wesentlicher Wachstumstreiber zeigt
sich immer mehr der steigende Bedarf der Automobilindustrie
an Strukturteilen. In Verbindung
mit den von Trimet anwendungsspezifisch
entwickelten Aluminiumlegierungen ist
dies zu einer weiteren tragenden Säule im
Automotive-Bereich geworden. „Unsere eigene
Metallbasis, das damit verbundene Werkstoff-Knowhow
und die Ausrichtung auf komplexe
Gussteile mit großer Bearbeitungstiefe
erweist sich auch für unsere Kunden als nachhaltige
Strategie. Der steigende Bedarf stärkt
die Standorte und schafft neue Arbeitsplätze“,
sagt Trimet-Vorstandsmitglied Thomas
Reuther.
Trimet versorgt alle namhaften Automobilhersteller
und -zulieferer mit maßgeschneiderten
Lösungen und Leichtbauteilen.
Mit einem Maschinenpark von 530 bis 4.100
Tonnen deckt das Unternehmen ein breites
Produktportfolio bei seinen Kunden ab.
Scholz-Gruppe kündigt
Restrukturierung an
Die Recyclingbranche ist derzeit in einer
schwierigen Marktverfassung, gekennzeichnet
durch niedrige Verkaufspreise und partielle
Überkapazitäten. Einer der größten Aluminiumrecycler
in Deutschland, die Firma Oetinger,
ist insolvent, während die Scholz AG
ein umfassendes Restrukturierungs- und Entschuldungsprogramm
ankündigt, das bis 2015
umgesetzt werden soll.
Die Scholz-Gruppe, die mit einem Ausstoß
von fast 10 Mio. Tonnen an Sekundärrohstoffen
zu den Marktführern beim Handel
und der Aufbereitung von Eisen und NE-
Metallen in Europa zählt und 2012 einen
Umsatz von 4,7 Mrd. Euro erwirtschaftete,
will sich künftig auf das Kerngeschäft
Recycling von Eisen- und NE-Metallen konzentrieren
und ihr Beteiligungsportfolio bereinigen.
So soll das Asiengeschäft deutlich
reduziert und die Geschäftsbeziehungen zur
australischen Recyclinggruppe CMA eingestellt
werden. Auch das Standortportfolio in
Europa wird bereinigt, Randaktivitäten wie
die Aluminiumproduktion sollen abgestoßen
werden. Im Übrigen werden die klassischen
Instrumente zur Ergebnisverbesserung und
Entschuldung eingesetzt: Kosteneinsparungen
und Stellenabbau, der bereits im zweiten
Halbjahr erfolgen soll.
Die Euler Hermes Rating hat unterdessen
das Rating der Scholz AG auf B herabgestuft;
der Ausblick wurde von „stabil“ auf „unbestimmt“
gesetzt.
Hydro-Ausschreibung
für Tonerde-Logistik
Hydro hat in Deutschland eine Online-Ausschreibung
für die Logistik zur Oxidversorgung
des Rheinwerks in Neuss platziert. Interessierte
Dienstleister sind aufgefordert, nachhaltigere
Lösungen mit einer weiteren Minderung der
spezifischen CO 2 -Emissionen vorzuschlagen.
Vom zweiten Halbjahr 2014 an soll der geplante
Kontrakt die gesamte Logistik für jährlich
300.000 Tonnen Tonerde abdecken. Der
Dienstleister transportiert dabei Aluminiumoxid
von den Ladestellen in Stade und vom
Rotterdamer Hafen. Er ist verantwortlich für
alle Zwischenlagerungs- und Umschlagsaktivitäten
bis hin zum Einblasen des Oxids in
die Silos im Rheinwerk. Außerdem umfasst
der Auftrag innerbetriebliche Umfuhren von
Sekundäraluminiumoxidmengen.
Der Logistikvertrag soll auch Nachhaltigkeitsaspekten
Rechnung tragen. „Hier sehen
wir noch großes Potenzial und deshalb steht
für uns die Ausarbeitung eines ganzheitlich,
innovativen Logistikkonzeptes sowie eine
langfristige Partnerschaft mit dem Logistikdienstleister
im Vordergrund“, sagt Irmtraud
Pawlik, in der Geschäftsfeldleitung von Rolled
Products verantwortlich für das Rheinwerk.
Die Ausschreibung betrifft ein Volumen
von mehreren Millionen Euro und startet
exklusiv auf der Ausschreibungsplattform
Cargoclix.
8 ALUMINIUM · 9/2013

NEWS IN BRIEF
Dubal products rated
for sustainable building
by LEED and DGNB
Products manufactured by Dubai Aluminium
(Dubal), UAE, have been declared suitable for
sustainable building practices, as per the criteria
defined by the US Green Building Council’s
Leadership in Energy and Environmental
Design (LEED) rating system and the Deutsche
Gesellschaft für Nachhaltiges Bauen (DGNB,
the German Sustainable Building Council).
Both declarations, which follow a rigorous
assessment process by an independent agency,
attest to Dubal’s commitment
to sustainability and
environment protection.
“This is a major development
for Dubal, as more
than 60 percent of our annual
production comprises
aluminium billets that are
used extensively by extruders
to produce construction
components – such as window
and door frames,” says
Walid Al Attar, executive
vice president for Marketing
and Sales. “The international
rating by LEED and DGNB
places these products in a
strong position to be specified
by end-users in the building
and construction industry
worldwide.”
The two sustainability
ratings are an important differentiator
in the local market,
where billets account
for the major proportion of
annual sales. Al Attar points
out that new laws have been
enacted in Dubai, whereby
the incorporation of sustainable
measures will be mandatory
in all new construction
projects in the Emirate as of
next year. “The suitability
of our products is tangible
evidence of Dubal’s support
for the government’s green
building agenda, simultaneously
confirming the success
of our efforts to produce
‘green metal’ as part of our
overall strategy to minimise
the impact of our business on
the environment,” he says.
ALUMINIUM · 9/2013
Rio Tinto abandons
divestment of
Pacific Aluminium
Mining giant Rio Tinto has abandoned the
plan to sell its loss-making aluminium operations
in Australia and New Zealand. “Following
a comprehensive review we have determined
that the divestment of Pacific Aluminium
for value is not possible in the current
environment and it will be reintegrated into
the Rio Tinto Alcan group,” the company
says. Pacific Aluminium’s operations include
four aluminium smelters as well as a bauxite
Please contact our sales
organization:
Essener Bogen 15,
22419 Hamburg, Germany
Phone +49 40 527 29 -101
or visit us at
www.yxlon.com
Technology with Passion
mine and an alumina refinery. Media have
recently reported that Rio Tinto plans to sell
13 aluminium facilities in Australia, Europe
and the US, as it looks to trim its Alcan business.
The Anglo-Australian company did not
disclose how much it expects to raise from the
sales.
Tom Albanese, Rio’s chief executive, said:
“The assets identified for divestment are
sound businesses that are well-managed with
productive workforces. But they are no longer
aligned with our strategy, and we believe
they have a bright future under new ownership.
We can choose the most opportune timing
to divest these assets, which may not occur
until the economic climate improves.”
Whatever your task
... we have the solution
Digital X-ray inspection of multiple parts and sizes
High-resolution images in 2D and 3D
Digital radiography and computed tomography
up to 600 kV
Manual, semi-automatic and fully automated
inspection

EVENTS
Weltleitmesse „Schweißen & Schneiden“ lädt nach Essen ein
Globales Innovationsschaufenster öffnet vom 16. bis 21. September 2013
Es ist wie bei den Olympischen Spielen:
Alle vier Jahre wird die Schweißen &
Schneiden zum globalen Treffpunkt der
fügetechnischen Fachwelt. 2013 kommen
die internationalen Experten der Füge-,
Trenn- und Beschichtungstechnik bereits
zum 18. Mal in Essen zusammen. Vom
16. bis 21. September präsentieren rund
1.000 Aussteller aus mehr als 40 Nationen
ihre Innovationen. Die Messe Essen
und ihr ideeller Partner DVS (Deutscher
Verband für Schweißen und verwandte
Verfahren e. V.) erwarten zudem rund
55.000 Besucher aus über 100 Ländern.
Schweißen & Schneiden 2009. Auch dieses Jahr erwartet der Veranstalter volle Hallen.
As in 2009 the organiser of Schweißen & Schneiden expects full halls
Als internationales Innovationsschaufenster
bietet die Messe das optimale Umfeld für die
Vorstellung neuer Produkte, Verfahren und
Dienstleistungen. Alle großen Industrienationen
und namhaften Hersteller sind in Essen
vertreten. Die größte Ausstellergruppe stellt
Deutschland mit 379 Unternehmen, gefolgt
von China (170 Aussteller), Italien (96) und
den USA (41). Die ausländische Beteiligung
liegt insgesamt bei rund 61 Prozent – ebenfalls
ein sehr guter Wert, der das Renommee der
Messe als wichtigste internationale Branchenplattform
für Wissenstransfer, Networking
und Nachwuchsförderung unterstreicht.
Viele Länder nutzen die Fachmesse, um
auf nationalen Gemeinschaftsständen die
Leistungskraft ihrer Unternehmen kompakt
zu präsentieren. Dazu zählen die USA, die
mit zwei Ständen in den Hallen 7 und 8 vertreten
sind, sowie China mit drei nationalen
Auftritten in den Hallen 7, 8.1 und 9.1. Weitere
Gemeinschaftsstände werden von Frankreich,
Japan, Taiwan, Italien sowie erstmals
Südkorea unterhalten.
Zu den innovativen Exponaten der Schweißen
& Schneiden zählen Geräte, Anlagen und
Werkstoffe – nicht nur für das Schweißen
und Schneiden, sondern auch für verwandte
Verfahren wie Löten, Wärmebehandlung
oder Thermisches Spritzen. So demonstrieren
13 Mitgliedsunternehmen der Gemeinschaft
Thermisches Spritzen e.V. (GTS) an einem
Gemeinschaftsstand in Halle 5 verschiedene
leistungsfähige Beschichtungsverfahren, die
hoch beanspruchte Oberflächen vor Verschleiß
und Korrosion schützen. Junge innovative
Unternehmen feiern Messepremiere.
Seit ihrer Premiere 1952 ist die Schweißen
& Schneiden auch eine Plattform für den
fachlichen Austausch, der in diesem Jahr zusätzliches
Gewicht bekommt. Unmittelbar vor
der Messe lädt das International Institute of
Welding (IIW) vom 11.-15. September 2013
zu seiner Jahresversammlung im Congress
Center Essen. Zu dieser Veranstaltung sowie
zur zweitägigen IIW-Konferenz „Automation
in Welding“ (16.-17. Sept. 2013) werden rund
1.000 Experten aus aller Welt erwartet. Während
der Messe werden außerdem renommierte
Fachleute auf dem DVS Congress 2013
Forschungsergebnisse, Marktentwicklungen
und Lösungen für Hersteller und Anwender
der Füge-, Trenn- und Beschichtungstechnik
vorstellen. Der DVS Congress 2013 findet im
Forum auf dem DVS/GSI-Gemeinschaftsstand
in Halle 12 statt.
Schweißen & Schneiden is inviting to Essen
It is just like the Olympic Games: every
four years, Schweißen & Schneiden becomes
the global meeting place of the
expert world of welding technology. In
2013, the international experts in joining,
cutting and surfacing technology
will come together in Essen for the 18 th
time already. From 16-21 September,
around 1,000 exhibitors from more than
40 nations will present their innovations.
Moreover, Messe Essen and its ideal partner,
DVS (German Welding Society), are
expecting around 55,000 visitors from
more than 100 countries.
As an international innovation showcase, the
exhibition will offer the best environment for
the introduction of new products, processes
and services. All the major industrial nations
and notable manufacturers will be represented
in Essen. The largest group of exhibitors will
be provided by Germany with 379 companies
followed by China (170 exhibitors), Italy (96)
and the USA (41). The foreign participation
will be around 61% in total – also a very good
value which highlights the reputation of the
fair as the most important international sectoral
platform for know-how transfer, networking
and the promotion of the next generation.
A lot of countries will also use the top-ranking
trade fair in order to present the efficiency
of their companies in a compact way on national
cooperative booths. These will include
the USA which will be represented with two
booths in Halls 7 and 8 as well as PR of China
with three national appearances in Halls 7, 8.1
and 9.1. Further cooperative booths will be set
up by France, Japan, Taiwan, Italy as well as,
for the first time, South Korea.
© Messe Essen
10 ALUMINIUM · 9/2013

Focus on Precision, Yield and Green
Set the benchmark in Aluminum Rolling!
siemens-vai.com
We know what we’re talking about when it
comes to aluminum rolling.
During the past five decades we have
supplied hundreds of new and modernized
mills that set the benchmark for producing
quality strip in an efficient manner. The
market is ever changing and now demands
highest yield and tolerances while
minimizing environmental impact.
Siemens VAI is at the forefront of this
challenge.
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.

W IRTSCHAFT
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
Die LME 3-Monatsnotierung konnte
sich nach dem regelrechten Ausverkauf
im vergangenen Monat wieder erholen
und notierte im Hoch wieder oberhalb
der Marke von € 1.400 per Tonne.
Unerwartet gute Konjunktur- und
Wirtschaftswachstumszahlen aus dem
Euroraum beflügelten alle LME-Basismetallnotierungen
und auch die Sorge um
den Liquiditätsengpass Chinas schien
mehr als unbegründet. Nachdem die
LME-Lagerhausbestände im Juni ein neues
Allzeithoch bei 5,45 Millionen Tonnen
markierten, erlebten sie im Juli einen wei-
teren Anstieg auf 5,49 Millionen Tonnen,
sodass die umstrittene LME-Lagerhauspolitik
weiterhin für sehr viel Zündstoff
und erhitzte Gemüter unter den Verbrauchern
sorgte. Daher werden die Stimmen
nach einem Eingreifen in das Geschehen
immer lauter.
Auf- bzw. Abschlag für 3-Monatstermin
Letzten 6 Durchschnittswerte LME
Juli 2013 33,88 Euro
Juni 2013 30,36 Euro
Mai 2013 24,80 Euro
April 2013 25,22 Euro
März 2013 30,79 Euro
Februar 2013 31,22 Euro
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
0
50
–50
Aluminium High Grade, Kasse
Letzten 6 Durchschnittswerte LME 2.500
Juli 2013 1.351,17 Euro
Juni 2013 1.376,16 Euro
Mai 2013 1.410,51 Euro
April 2013 1.424,60 Euro
März 2013 1.475,92 Euro
Februar 2013 1.538,20 Euro
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
2.000
1.500
1.000
Aluminium Lagerbestände
Letzten 6 Monatsendwerte LME
Juli 2013 5.478.525 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.
Februar 2013 5.162.050 t.
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
6.000
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.
12 ALUMINIUM · 9/2013

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)
Juni 33,0 -8,0 54,6 6,9 161,0 20,6 49,1 -0,3
Juli 34,8 -5,0 56,0 7,1 166,4 0,9 46,9 -7,4
+/-
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
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- und Ziehprodukte
14 ALUMINIUM · 9/2013

...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

ECONOMICS
Aluminium S.A. increases production, reduces costs
G. Djukanovic, Podgorica
Aluminium S.A., earlier known as Aluminium
of Greece (AoG) and Aluminium
de Grèce (ADG), is the sole vertically
integrated aluminium producer in Europe
with all production facilities concentrated
in one location. It is the largest alumina
producer in Southern and Eastern Europe
and the second largest primary aluminium
producer next to Romanian Alro.
Aluminium S. A., located in St Nicolas at the
north coast of the Gulf of Corinth, started
production in 1966 as a Pechiney plant, then
under the name ADG. Later it was a base
for the development of the aluminium manufacturing
industry in Greece with numerous
facilities all over the country. Today annual
turnover amounts to more than €2bn. Over
40,000 people are directly and indirectly employed
in the sector. In 2003 ADG became
part of Alcan after the Canadian company
took over Pechiney in France. Alcan sold it to
the Greek private company Mytilineos Group
in 2005.
Aluminium S.A. achieved a steady production
in the past two years of 164,000 tpy of
aluminium (124,000 tonnes of alloyed billets
and 40,000 tonnes of slabs) and around
800,000 tpy of metallurgical grade alumina.
According to a company presentation sales
amounted to €506m and Ebitda to €21m in
2012, whereas sales were €521m in 2011 and
Ebitda €32m. In recent years, since it became
a fully owned subsidiary of Mytilineos Group,
Aluminium S.A. has not published separate
financial reports.
In view of market uncertainty and falling
aluminium prices, the management took the
initiative to develop a strategic growth plan.
The so-called ‘Future’ programme, launched
in 2011, refers to the implementation of a
new, ambitious plan for cutting operating
costs, and to a preliminary agreement for the
acquisition of the bauxite operations of S&B,
the largest bauxite mining company in Greece.
The Future programme – scheduled for completion
by the end of this year – focuses on
ten key areas that the company is addressing.
In 2012 the group launched a new ‘Mellon’
programme (‘Mellon’ = ‘Future’ in Greek),
a large-scale cost-saving programme in order
to further internationalise the group’s metallurgy
and mining business activity. The Mellon
programme will remain a key priority for the
group in 2013, as it works as a crucial safety
valve in the challenging business environment
of limited liquidity. According to this
programme cost savings of €110m a year are
planned and some €90m of cost benefits have
already been achieved. The remaining amount
mainly relates to bauxite sourcing and to production
mergers.
In November 2011, Mytilineos Group and
S&B Industrial Minerals S.A. announced the
initial agreement for the gradual acquisition
of S&B’s bauxite operations by Mytilineos’
View of the cogeneration plant at Aluminium S.A.,
with two HRSGs and two gas turbines
subsidiary Aluminium S.A. However, following
completion of thorough due diligence, a
final agreement was not reached. Evaluating
the challenges presented by the domestic and
international environment, the two companies
will continue to pursue ways to improve the
competitiveness of bauxite mining activities,
whereas their commercial collaboration will
continue without impediments.
Aluminium S.A. has full ownership of Delphi-Distomon
bauxite mines, the second largest
in the country, with current annual production
of around 650,000 tonnes. It is located in
the nearby Amfissa region and employs some
100 people. Despite the fact that the area
is rich in bauxite with over 100m tonnes of
proven reserves (of a total of 650m tonnes in
Greece), the company started importing tropical
bauxite in 2000 (about 200,000 tpy) that is
mixed with Greek bauxite in a process called
© Metka
‘sweetening’. The reason for this is to facilitate
the process because Greek bauxite has a
relatively high content of silica which is more
difficult to process.
Commercial contracts with Glencore
The Mytilineos Group signed a USD2bn deal
in July 2008 to provide Swiss-based trader
Glencore International (now Glencore Xstrata
Plc) with all surplus alumina over a ten-year
period. AoG will deliver more than 5m tonnes
of alumina to Glencore during the period.
Production of alumina will amount 770,000
to 800,000 tpy during the FY2012-2014 period
with a selling price of 13.5% of the LME
3-month aluminium price, which refers to the
contract price and market price for remaining
volumes sold in the spot market (according to
National Securities). The alumina refinery operates
at full capacity of 800,000 tpy; around
60% of the production is sold to third parties,
mainly to Glencore for the contract-linked
price of about 14% of the LME 3-month aluminium
price (according to Eurobank Equities
Research).
In January 2013 Aluminium S.A. signed
a new contract with Glencore for the sale of
75,000 tonnes of aluminium in billets and
slabs, for a total of USD200m. The metal will
be exported to the EU and US markets from
January 2013 to June 2014.
Production costs decreasing
Alumina production costs have been exceeding
USD300/t in recent years while Aluminium
S.A. has been ranked in the third quartile.
After implementing significant cost reduction
measures the cash production costs now stand
at around USD250/t (2013 estimate) which
corresponds to the first to second quartile of
the global alumina cost curve.
The smelter costs were ranked in the fourth
quartile of the global cost curve until recently.
The management expects that after full and
successful implementation of ‘Mellon’, production
costs will be around USD2,000/t. This
would place the company in the second quartile
of the cost curve. However, it is more realistic
to expect costs hardly below USD2,200/t
(3 rd quartile), mainly due to relatively high
electricity prices. In 2013 production costs are
expected to be around USD2,300/t, according
to company reports.
16 ALUMINIUM · 9/2013

E CONOMICS
Major investments in
environment protection
Since the construction of the cogeneration
power plant was completed in 2008 (€191m)
investments of Aluminium S.A. have comprised
bauxite residues recovery facilities and
filter presses, with the installation of two additional
presses in the last few years. At the
same time, studies have been carried out to
examine the potential for the utilisation of
bauxite residues in other industry sectors.
The company’s goal is to discharge the full
quantity of bauxite residues ashore, in an area
specially set aside for this within its terrain.
Other investments aim at increasing aluminium
production to 174,000 tpy in 2014
and alumina production to 810,000 tpy.
Electricity costs
According to the Regulating Authority for
Energy (RAE) procedure issued in May 2012,
the provisional electricity price for Aluminium
S.A. is 42 €/MWh (plus €6/MWh tax and
transfer costs, according to Eurobank Equities
Research). It is estimated that at this price
Aluminium S.A. has been subsidised by some
€10m annually.
Another €10m a year could be saved by
using steam from the cogeneration plant. Application
of the provisional price, according to
the rationale of the RAE decision, refers to
all operating hours of Aluminium S.A., in the
light of the single-zone tariff that matches its
consumption profile for the entire period of
the day; this will remain in force until the final
decision by the arbitrators to whom Aluminium
S.A. and PPC (the national electricity dis-
© Mytilineos Group
DRYPLUS
Less Sludge – Less Costs
Weniger Schlamm – Weniger Kosten
Drasc reducon of sludge volumes from anodizing lines
Überragende Reduzierung der
Schlammmengen von Eloxal-Linien
With DRYPLUS you reduce
by 50% the volume of aluminium hydroxide sludge!
Mit DRYPLUS reduzieren Sie 50% des
Aluminiumhydroxid-Schlamms!
Considered Parameters (waters treatment from an
anodizing line with 30.000 A installed capacity)
Berücksichgte Parameter (Wasserbehandlung
einer Eloxal-Linie mit einer Kapazität von 30.000 A)
Standard
Standard
With Dryplus
Mit Dryplus
Dry percentage of the sludge [%]
Anteil des Trockenschlamms [%]
Sludge producon [tons/year]
Schlammprodukon [Tonnen/Jahr]
Esmated Cost for sludge disposal [€/ton]
Geschätzte Kosten für die
Schlammentsorgung [€/Tonne]
Cost for disposing of the sludge [€/year]
Kosten für die Schlammentsorgung [€/Jahr]
20% 45%
1300 578
80 80
€ 104.000 € 46.222
Total Saving [€/year] - Ersparnis [€/Jahr] € 57.778
Technical and nancial data are indicave and only provided for informaonal purposes. Italtecno will be keen to submit a tailor-made proposal. Feel free to ask!
Technische Daten und Kosten sind indikav und nur zu Informaonszwecken bereitgestellt. Italtecno wird Ihnen gerne ein persönliches Angebot unterbreiten. Fragen Sie uns einfach!
Via Gino Marinuzzi 38 - 41122 Modena (Italy) - Tel. +39 059 280362 - Fax +39 059 280462
info@italtecno.com - www.italtecno.com - www.diecleaningplant.com
ALUMINIUM · 9/2013 17

ECONOMICS
tributor) have referred their dispute (source:
Annual report 2012). This information leads
to the conclusion that the gas cogeneration
power plant, built within the production complex
of Aluminium S.A., has not contributed
to reducing electricity costs to an extent that
would be suitable and profitable for Aluminium
S.A.
This price per megawatt hour is lower
by about €20/MWh than the price that PPC
had been charging Aluminium S.A. following
a unilateral decision and despite the lack of
contract for the period of July 2010 up until
mid-May 2012 (date when the decision was
made by RAE, deciding on a temporary price).
The impact of CO 2 emissions charges implemented
in 2013 may additionally increase
electricity costs by €6/MWh unless the state
implements subsidises for energy intensive industries,
including Aluminium S.A.
Exemplary in safety
Aluminium S.A. has a long tradition in safety
performance since it was part of the Pechiney
group, and the management is very proud of
that. It is regarded as one of the safest aluminium
plants in the world for workers, with
only few accidents a year (and only one injury
at work in 2006) .
In December 2012 a new collective agreement
was made between the management of
Aluminium S.A. and the company’s labour
union. The agreement resulted in preserving
all employment positions and the production
capacity of the plant as well as significant cost
streamlining on a viable and long-term basis.
Technical features
Aluminium S.A. uses tried and tested Pechiney
technology, a point-feeder system, enclosed
pot cells and pre-baked anodes. Potlines A
and B (since 1986) operate at 70 kA (520 pots)
and potline C at 90 kA (since 1971, 260 pots).
Since 1995 the plant has been equipped with
central computer control and graphic tracking
of the production process in all potlines.
Current efficiency is 93% and electricity consumption
is 13,200 kWh/t. Consumption of
anodes is 405 kg/t Al , aluminium fluoride is 10
kg/t, alumina 1,900 kg/t, so the plant has the
lowest specific consumption of raw materials
and consumables compared to all other producers
in the region. Aluminium S.A. processes
around 1.4m tonnes of Greek bauxite
and 200,000 tonnes of imported (tropical)
bauxite; it produces around 800,000 tpy of
alumina (460,000 tpy for export) and 164,000
tpy of primary metal (around 90,000 tpy for
the Greek market). The anode plant has a production
capacity of 90,000 tpy of anodes.
Average pot life is 100 months (more than
eight years), which is one of the best results for
this type of cell and technology in the world.
The plant’s port is capable of accommodating
and serving ships of tonnages up to 50,000
tonnes. It is equipped with three electric rail
cranes, the alumina ship loader and all necessary
storage facilities for raw materials and
products. The loading installations for the alumina
cargo to be exported (bulk cargo) can
achieve loading rates exceeding 600 tph.
The smelter uses Tardis equipment for its
dross handling. Tardis is a fully patented process
of rapid cooling and pressing. The equipment,
which was awarded a Queen’s Award
for Enterprise in the Innovation category, has
been designed to maximise aluminium recovery
from dross, whilst eliminating the associated
dust and fume.
The new 334-MW high-efficiency combined
heat and power (CHP) plant, or cogeneration
plant, is located within the complex
of Aluminium S.A. It is connected to the regional
gas pipeline that comes from Russia
In July the EU Commission has referred Greece
to the European Court of Justice for failing to
comply with two distinct Commission decisions
that ordered Greece to recover incompatible
state aid from three Greek casinos and from Aluminium
of Greece S.A. (AoG). In both cases, over
two years after the Commission decisions, the
full aid amounts have still not been paid back.
The EU Commission requested Greece to
recover incompatible state aid in the form of
preferential electricity tariffs from AoG. The aid
amount is calculated as the difference between
PCC’s revenues from the standard tariff between
and across Bulgaria to Athens and the port of
Piraeus. The plant came into operation in 2008
and is equipped with the latest technology. It
operates using natural gas and, apart from
electricity, produces steam which is used in
the alumina production process. Any surplus
electricity produced is fed into the national
electricity grid.
Author
Goran Djukanovic is an independent aluminium
market analyst. He is located in Podgorica, Montenegro.
Email: gordju@t-com.me.
EU Commission refers Greece to court for failure
to recover incompatible aid from AoG
January 2007 and March 2008 and the revenues
from the tariff that was actually applied to AoG
in the same period. The Commission calculated
the aid principal as amounting to 17.4 million
euros.
The aid given to AoG has not been recovered
up to date. The recovery procedure has been
suspended by a national court, in clear violation
of EU law. AoG has appealed the Commission’s
2011 decisions before the EU General Court.
However, no interim measures have been requested
nor granted and the appeals have no
suspensive effect.
Source: Eurobank Equities Research
© Djukanovic
18 ALUMINIUM · 9/2013

E CONOMICS
Aluminium – The transportation material of the future
F. Awadhalla, Dubal
The importance of aluminium in the
transportation sector is without question.
In the automotive segment, in particular,
the growth in demand and application of
aluminium is, for several reasons, on a
continuous expansion trend. The article is
based on a presentation the author gave
at the CRU World Aluminium Conference
2013 in London.
The diversity of applications for aluminium is
huge. It is used in virtually every sector – from
cooking pots, through housing and other infrastructure
construction, to all types of transportation,
military and marine applications.
This is reflected in the growing volumes of
aluminium used worldwide: the annual growth
rate of primary aluminium consumption is 4-
6%. This is double the growth rate of the global
population, GDP and IP over the last five
years.
At present, more than 50% of aluminium
consumption is utilised in two sectors: transportation
and construction. Analysts predict
that aluminium consumption will almost double
in the next ten years, with the greatest
growth taking place in the transportation and
construction sectors.
Within the transportation sector, aluminium
is used extensively in all sub-sectors –
namely aviation, marine transport, space and
land transportation. In aviation, about 33,500
new aeroplanes and freighters are required
between 2011 and 2030, with a total market
value of USD4 trillion. In marine transportation,
the usage of primary aluminium in
ship-building will grow by 2.2% in the next
five years. For space vehicles, the forecast
growth in aluminium usage is around 3.5%.
The growth trend in land transportation is
predicted at 4.3%, with aluminium usage
growing from 15 million tonnes in 2015 to 19
million tonnes in 2020.
This reflects the increasing use of aluminium
as a substitute for other metals in the
automotive sector. The reason for this is the
numerous advantages offered by aluminium,
summarised as follows:
• Efficiency – Aluminium is unmatched for its
contribution to fuel conservation, due mainly
to the associated reduction in vehicle weight.
Statistics show that for every 10% reduction
in weight a fuel-saving of 5-7% is achieved.
The lighter weight of aluminium vehicle bodies
also means reduced frequency of charging
© Dubal
the battery in hybrid electric cards, which will
no doubt make these vehicles more competitive
and thus more attractive to consumers.
• Sustainability – Aluminium is the most
abundant metallic element in the earth because
it is infinitely recyclable. Nearly 75% of
aluminium produced in 1988 is still in usage
and almost 90% of automotive aluminium is
covered and recycled without degrading the
metal’s properties.
Fadi Awadhalla at the CRU conference
• Safety – Many people wrongly believe that
the lighter weight of aluminium-based vehicles
reduces their safety. However, the opposite
holds true due to the mechanical properties
of aluminium (especially compared to steel).
The density of aluminium is one-third that of
steel, which means that car manufactures can
double the cross-section of metal plates and
still produce a lighter-weight vehicle. Also,
because of the mechanical folding property of
aluminium, it can absorb double the amount
of crash energy compared to steel.
• Durability – Most aluminium alloys are engineered
for extended service life. Moreover,
aluminium is known for being long-lasting
and rust resistant, which thus reduces the need
for rust repair and increases the vehicle life
span.
• Performance – All car manufacturers look
to provide end-users improved performance.
Since vehicles made with aluminium are
lighter in weight, they perform better overall –
they accelerate faster, have a shorter braking
distance, and provide full maneuverability
and handling for the driver.
• Design – Aluminium provides greater flexibility
for designers to design the shape desired
to perform better in different applications.
• Cost-effectiveness – Lighter-weight vehicles
boast lower fuel consumption and highly reliable
parts with reduced maintenance liabilities.
The net result is greatly improved cost of
ownership to consumers.
At the outset of aluminium usage in the automotive
sector, the metal was used primarily
in four areas – wheels, engine, transmitter and
heat exchangers. The current usage is vastly
greater, with aluminium being used in place of
steel for many different parts of the vehicle.
Based on this, the potential growth of aluminium
usage in the automotive industry is set to
from 9-16%.
Naturally, a key factor in the switch to aluminium
usage is the environmental benefits.
Statistics show that for every 100 kg reduction
in vehicle weight, the fuel consumption
declines by 0.3 to 0.5 litre per 100 km. This
then reduces CO 2 emissions from 0.8 to 1.1
kg per 100 km.
In closing, the success of the aluminium
industry going forward depends on how efficiently
it is managed – from the raw materials
(alumina) to power station set up and smelter
productivity and value added products in the
casting operations. By maintaining our focus
on the correct parameters, our industry will
continue to grow sustainability – with minimal
impact on the environment.
Author
Fadi Awadhalla is senior casthouse manager at
Dubai Aluminium, UAE.
Planung, Konstruktion und Ausführung
von Industrieofenanlagen
Konstantinstraße 1a
41238 Mönchengladbach
Telefon +49(0)2166/987990
Telefax +49(0)2166/987996
E-mail info@inotherm-gmbh.de
Internet www.inotherm-gmbh.de
ALUMINIUM · 9/2013 19

ECONOMICS
Primary aluminium industry during the first half of 2013, Part II
Rudolf P. Pawlek, Sierre
This overview covers the events of
the primary aluminium industry
during the first half of the year
2013. While Part I, published in
ALUMINIUM 7-8/2013, focused
on Africa, America, Australia and
Europe, Part II looks at the Middle
East and Asia. One of the latest
highlights in the aluminium industry
was the announcement of Mubadala
Development Co. of Abu Dhabi and
ICD of Dubai to merge the businesses
of Dubai Aluminium and
Emirates Aluminium and thus create
‘Emirates Global Aluminium’ – the
fifth-largest global aluminium company
by production.
MIDDLE EAST & ASIA
ABU DHABI: In June Emirates Aluminium
(Emal) celebrated the installation of the final
steel structure for the potline of its Phase II
expansion. With the last of 120 specially designed
steel structures in place, all the major
civil and mechanical work on the world’s longest
single potline of 1.7 km is complete by
now, and Emal remains on target to deliver
its ambitious expansion plans. The first steel
structure was raised in July last year, which
means that completion was within the anticipated
target of 12 months. The work was done
without a single lost time injury – the industry
standard for measuring success in health and
safety.
Emal’s Phase II expansion project will increase
aluminium production to 1.3m tpy by
the end of 2014, from today’s 800,000 tpy.
Early works on the estimated USD4.5bn
Phase II expansion began in early 2011, making
Emal one of the largest industrial projects
in the UAE outside oil and gas and one of the
key projects leading to the diversification of
the UAE’s economy.
BAHRAIN: Aluminium Bahrain (Alba) has
begun a bankable feasibility study to determine
the viability of the expansion of its sixth
potline. The expansion project is expected to
add another 400,000 tpy to the company’s current
capacity of 890,000 tpy. Alba will use Dubal
DX+ technology in the bankable feasibility
study. Dubal currently has five pilot DX+ pots
which began operating at 420 kA and are now
running at 440 kA. DX+ is an updated version
of the DX technology which is in use at Dubal
Ingots from Emal, waiting for shipment
and Emal Phase I plants.
At the end of December 2012, Alba announced
it remains on track in broadening
its production capacity by increasing its line
current of Potline 5 from AP30 to AP36 technology.
The upgrade will enable Alba to boost
output since each 1 kA increase is expected
to yield 950 tpy of extra aluminium production.
The Alba team succeeded in achieving
this goal without any significant capital investment.
Plans are also underway to achieve the
same level of success in Potlines 3 and 4.
In June Alba announced that its process
technology achieved a significant milestone
with the upgrade of Potline 5 to AP37 technology
following an increase in the line current
to 370 kA. The upgrade increases the smelter
capacity by around 10,000 tpy.
➝
© Emal
Primary aluminium smelters in the Middle East:
Nameplate capacities and shutdown capacities on a temporary basis
Compiled by R. P. Pawlek, June 2013
Country
MIDDLE EAST
Location Nameplate
Capacity
(tpy)
Abu Dhabi Taweelah 800,000
Azerbaijan Ganja 50,000
Bahrain Askar 900,000
India Jharsuguda 500,000
Korba 900,000
Renukoot 345,000
Hirakud 213,000
Angul 475,000
Indonesia Kuala Tanjung 265,000
Shutdown
Capacity
(tpy)
Iran Arak 90,000
Arak (2) 110,000
Bandar Abbas 110,000
Bandar Abbas (2) 147,000 100,000
Japan Kambara 20,000
Kazakhstan Pavlodar 250,000
Malaysia Sarawak 120,000 60,000
Oman Sohar 390,000
Qatar Mesaieed 625,000
Tajikistan Regar 450,000 175,000
Turkey Seydisehir 65,000
UAE Jebel Ali 1,040,000
20 ALUMINIUM · 9/2013

ECONOMICS
Primary aluminium smelters in China:
Nameplate capacities and shutdown capacities on a temporary basis
Compiled by R. P. Pawlek, June 2013
Location Nameplate
Capacity
PR CHINA
(tpy)
Aba 100,000
Baise Yinhai 200,000
Baotou Shi 610,000
Baotou East Hope 400,000
Changjiang 62,000
Chiping Xinfa 550,000
Chongqing Tiantai 55,000
Chongqing Dongsheng 50,000
Chuangyuan 100,000
Danjiankou Shi 50,000
Datong Xian 260,000
Shutdown
Capacity
(tpy)
Dengfeng 65,000 20,000
Dianneng Gejiu 50,000
Dongfang Xiwang 780,000
Emeishan 355,000
Faxiang 70,000
Fukang 413,000
Fushun Shi 350,000 70,000
Gansu Lonxi 240,000
Gongyi 25,000
Guangxi Baise Xinghe 320,000
Guangyuan Qimingxing 114,000
Guanlu (old) 110,000
Guanlu (new) 220,000 220,000
Guanyuan Aostar 420,000
Guiyang Shi 240,000
Guizhou 410,000
Haizhou 40,000
Hejin Xian 120,000
Hongjun 1,060,000 60,000
Honglu Aluminium 150,000
Huadong 70,000
Huanghe 80,000
Huasheng Jiangquan 112,000
Huaxin 70,000
Huayu 100,000
Jiaozuo Shi 420,000
Jilin 65,000
Jinning 350,000
Jingxi 160,000
Jnneng 80,000
Ke’ao 135,000
Laibin Yunhai 250,000
Lanjiang Shi 30,000
Lanzhou Shi 700,000
Lanzhou Liancheng 260,000
Linfeng 160,000
Lintao 50,000
Linzhou 240,000
Longlin 50,000
Longquan Aluminium 400,000
Longxiang 55,000
Meishan Qimingxing 130,000
Mianchi Aluminium 80,000
Nanping Shi 73,000 20,000
Nanshan 406,000
Ningxia 370,000
Ningxia St. Dehua 50,000
Nongliushi Xinjiang 590,000
Panshi Xian 25,000
Pingguo Xian 140,000
Pingyin 26,000
Qiaotou 350,000
Qinao 90,000
Qinghai 436,000
Qinghai Huanghe 500,000
Qinghai Xinheng 500,000
Qinghai Xinye 575,000
Qingtongxia Shi 685,000
Qinyang 500,000 70,000
Qiya 400,000
Sanmenxia Shi 120,000 20,000
Shandong Aluminium 78,000
Shandong Donghai 200,000
Shangdian 125,000
Shanxian Hengkang 220,000
Shanxi-Huaze 350,000
Shenhuo (old) 160,000 32,000
Shenhuo (new) 420,000 110,000
Shihezi 400,000
Sichuan Emei 350,000
Sichuan Qiya 350,000
Taian 50,000
Taiyuan Shi 100,000
Tianyuan 130,000 40,000
Tongshuan Xinguang 110,000
Tongshuan 150,000
Tongshun 50,000
Wanji Aluminium 530,000
Wujiaqu 740,000
Xichuan 90,000
Xiezhou 330,000
Xinfa 175,000
Xinjang Yihe 400,000
Xinjiang 370,000
Xinjiang Easthope 860,000
Xinwang 76,000
Yangquan Shi 60,000
Yangquan Aluminium 68,000
Yichuan Aluminium 600,000 60,000
Yinhai Aluminium 100,000
Yongan Aluminium 60,000
Yongcheng Xian 60,000
Yongcheng City 500,000
Yugang Longquan 600,000
Yulian Power 120,000
Yungcheng Shanhe 65,000
Yuncheng Shi 220,000
Yunnan 500,000
Yunnan Dongyuan 240,000
Yunnan Runxin 50,000
Yunnan Yongxin 35,000
Zhaofeng Aluminium 61,000
Zheijiang Huadong 70,000
Zhengxing Aluminium 120,000 70,000
Zhengzhou Shi 58,000
Zhonghe 495,000
Zhongfu 308,000
Zhongning Aluminium 370,000
Zibo Shi 55,000
Zouping 141,000
Zunyi Xian 242,000
For two consecutive years, Alba has achieved
record output through deployment of lean
management techniques and operational efficiency
initiatives. In January, the company
announced that the 2012 production was
890,217 tonnes, which is an increase of 8,907
tonnes on 2011 figures.
CHINA: In January Chalco announced it
purchased a 23.66% stake in Ningxia Electric
Power Group in what the company considers
to be a milestone in its cost-cutting efforts.
Chalco completed the purchase from Huadian
Power International Corp. at the end
of 2012, becoming Ningxia Electric’s biggest
shareholder. At present, Ningxia has a thermal
power generation capacity of 3,874 MW,
wind electricity capacity of 1,039 MW and
photovoltaic power generation capacity of 103
MW. Ningxia Electric also has a coal reserve
of 2.38bn tonnes and a production capacity
of 16m tpy.
In January the country’s Ministry of Industry
and Information Technology (MIIT),
National Development and Reform Commission
(NDRC) and ten other ministries set out
guidelines for the future structure of nine industries,
including aluminium, rare earths and
steel. According to the guidelines, China aims
to have a few aluminium business conglomerates
with core competitiveness and international
influence by 2015, and have the top 10
smelters accounting for 90% of the country’s
total production capacity.
Other likely players in consolidating China’s
aluminium industry are smelters in Henan
province, where combined output of aluminium
would be higher than Chalco’s. To meet
the top 10 / 90% target, major smelters in Henan
province may have to be merged into one,
22 ALUMINIUM · 9/2013

al
Casting Confidence
Built on innovation and refined through experience, Wagstaff billet and ingot casting
technologies are a gateway to profitability. Casthouses around the world rely on
the history, experience, and service offered by Wagstaff to foster confidence within
the casting operation. That confidence is valuable and necessary to safely cast
aluminum and to ultimately maximize profits in the marketplace.
The leader in direCT
Chill CasTing
TeChnology
Casting Machines
rolling ingot Casting
systems
Billet Casting systems
automation
Metal level Control
Worldwide service and
support
To find out how your operation can increase casting confidence
Call +1 509 922 1404 || www.wagstaff.com

ECONOMICS
as China has dozens of smelters of that similar
size. Such talk has been initiated years ago.
Henan is China’s largest province for
aluminium production, with the major five
companies being Zhongfu Industrial, Shenhuo
Group, JiaoZuo WanFang Aluminum
Manufacturing Co., Henan Wanji Aluminium
Co. and Henan Yugang Longquan Aluminum
Co. All of them have a production capacity of
0.7-0.8m tpy. Zhongfu is publicly traded on
Shanghai Stock Exchange, while both Shenhuo
and Jiaozuo are listed on Shenzhen Stock
Exchange.
In February it was announced
that China’s government aims
to “vigorously” eliminate obsolete
aluminium capacity in 2013
through economic measures such
as differential power rates. The decommissioning
of technologically
backward smelters is a key work
area in 2013.
Economic measures such as
power rates differentiation will
be studied and employed so as
to raise production input costs to
impel obsolete smelters to exit the
market. In addition, the authorities
aim to set new entry requirements
for the aluminium industry, as already
exist for secondary aluminium
producers.
China had 27.65m tonnes of
aluminium capacity at the end of
2012, with utilisation rates at only
72%. Only 45% of the total capacities
are operated with self-run
power stations, while those relying
on the state grid’s power are
deeply in the red.
Metal prices are expected to
vary little in 2013, with periodic
recovery opportunities depending
on global monetary easing and on
China’s investment policies.
China’s drive to crack down on
surplus non-ferrous metal production
capacity will extend to small
carbon cathode and anode plants as of May.
The guidelines place anode block plants
with an annual capacity of 80,000 tpy or less,
and cathode block plants with a capacity of
20,000 tpy or less, in the government’s ‘restricted’
category, meaning new investment
proposals for such small plants are likely to
be rejected. Those operating existing facilities
that fall under the guidelines may face increasing
regulatory and cost pressures.
Such small capacities proliferated on the
back of the government’s post-financial-crisis
stimulus package, spurred by local government
incentives aimed at creating employment.
But widespread overcapacity and consequent
cost pressures throughout the aluminium industry
are now driving state policies aimed at
reversing the trend. In any case, small capacity
units have already begun to cut production
amid low metal prices, particularly in high-cost
areas such as Henan province.
Cathode and anode exporters are unlikely
to be affected by the rule change, since most
plants in China’s primary export regions are
more sizeable.
Extrusion billets from Dubal
Early in April it was reported that China consumed
0.5% less energy year-on-year in 2012
per tonne of primary aluminium produced.
Electricity consumed per tonne of primary
aluminium dropped on average to 13,8 kWh
in 2012, down 69 kWh from a year ago, and
equal to a reduction in carbon dioxide emission
of 63 kg/t of aluminium produced. China
thereby saved 1.4bn kWh in 2012.
DUBAI: In March Dubai Aluminium (Dubal)
announced it has expanded its interest in
the upstream (raw materials) sector by purchasing
a 20% stake in a calciner development
project as part of a joint venture with Sinoway
Carbon Energy Holdings, Hong Kong, for
an undisclosed sum. The new venture, known
as Sinoway Carbon Co. Ltd, entails the construction
of a 560,000 tpy petroleum coke
calciner in Shandong, China.
Calcined petroleum coke (CPC), is a strategic
raw material for the aluminium smelting
industry, where it is used in the manufacture
of carbon anodes for the electrolytic process.
Dubal will be entitled to an annual off-take
volume of CPC for its smelting operations.
The Sinoway calciner is being
built in two equal phases. Construction
of the first phase was
completed in May. The second
phase is scheduled for completion
in Q4 2013. The plant will employ
Chinese shaft technology –
a well-proven, simple-to-install,
easy-to-operate system that gives
better yield than other technologies
at substantially lower capital
and operating expense. China has
a surplus supply of green petroleum
coke (GPC). Indeed, China
currently produces more than
40% of annual global GPC/CPC
production, with several GPC refineries
being in close proximity
to the Sinoway development site.
Dubal’s investment in Sinoway
represents a strategic opportunity
to mitigate the company’s supply
and quality concerns, thus contributing
to business continuity.
CPC is one of the main drivers
for cost of production, and is hence
an important factor in the business
equation. With a secure supply
of suitable quality CPC from Sinoway
calciner, Dubal will be well
placed to counter this trend, with
direct benefits to the bottom-line.
At the beginning of June, in a
move that will form a new industrial
giant in the UAE, Mubadala
Development Co. of Abu Dhabi and the Investment
Corp. of Dubai (ICD) announced the
creation of Emirates Global Aluminium. This
jointly-held, equal-ownership company will
integrate the businesses of Dubal and Emal
and has plans for significant local growth and
international expansion.
The accord builds on a successful partnership
that started with the formation of Emal
in 2006, a joint venture of Mubadala and Dubal.
Emirates Global Aluminium will have an
aggregate enterprise value of more than US-
© Dubal
24 ALUMINIUM · 9/2013

E CONOMICS
D15bn, and it will be the fifth-largest global aluminium company
by production, once Emal’ Phase II expansion project is complete
in the first half of 2014.
Building on the heritage of Emal and Dubal, the new company
will look to expand along the value chain, from aluminium smelting
to alumina refining and bauxite mining overseas. Given its
scale and growth, Emirates Global Aluminium will also continue to
attract downstream manufacturing as well as ancillary businesses
related to aluminium smelting and alumina refining, thereby indirectly
creating additional jobs.
The new company will accelerate employment with 2,000 direct
jobs being created by 2020, adding to more than 6,200 direct jobs
(Dubal 3,800; Emal 2,500) already in existence. A further 6,000
indirect jobs will be generated, delivering total employment of over
33,000 people by the UAE aluminium sector through the end of
this decade.
Emirates Global Aluminium will serve over 440 customers in
55 countries, with a joint production capacity of 2.4m tpy of aluminium
on the completion of Emal Phase II.
Pending required approvals, the formal commencement of
joint operations is expected to be completed within the first half
of 2014.
The combination agreement signed by Mubadala and ICD unifies
the Jebel Ali and Taweelah smelter assets, as well as interests
in Guinea Alumina Corp. and Cameroon Alumina Ltd.
Energy costs for major aluminium producers range from
USD255-368/t in the Middle East, while in India electricity prices
range from USD514-904/t.
INDONESIA: The Indonesian government will completely take
over Indonesia Asahan Aluminium, known as Inalum, in November,
although negotiations are still ongoing. That is what the Indonesian
Industry Minister M.S. Hidayat told journalists in June.
He added that the government had already earmarked Rp7 trillion
(USD707m) for the take-over. Originally the government had
plans to sell its stakes to other investors, but then changed mind
because it wants to turn Inalum into a new state-owned enterprise.
Inalum is currently 58.88% controlled by Japanese consortium
Nippon Asahan Aluminium and 41.12% controlled by the Indonesian
government.
TURKEY: In April the European Bank for Reconstruction &
Development (EBRD) announced it has drafted plans to promote
the use of pre-baked anode technology in the Turkish aluminium
smelter through a USD50m loan to Eti Aluminyum. The money
would help to modernise the company’s aluminium smelter located
in Konya, in southern Anatolia, by converting the existing
Søderberg electrolysis technology to proven pre-baked anode
technology. The privately-owned company produces alumina, hydrate,
liquid aluminium and other alumina products from its bauxite
mining operations, located south of Konya.
Eti Aluminyum had promised to develop advanced corporate
social responsibility practices, reporting publicly on such policies
from 2015. It had also agreed to develop and implement integrated
energy and carbon management systems under ISO 50001 standards.
The new unit would meet European Union standards and
best available technologies.
The company’s entire modernisation plan should cost
USD232m, and involve the phasing out or upgrading of the old
Soviet-designed open cell electrolysis pots. Eti Aluminyum awaits
final decision on the loan from the EBRD board of directors. ■
© iStock
CNC - Spezialmaschinen
Aluminium ist beständig
– wie eine
MAKA
5-Achs-Bearbeitung von
www.maka.com
¬ Aluminiumprofilen
¬ Aluminiumgussteilen
¬ Aluminiumblechen
¬ Aluminium-Verbundstoffen
Anwendungsbereiche
In der Automobil- und Aircraftindustrie,
dem Fenster- und Fassadenbau und mehr ...
MAKA 5-Achs-Bearbeitungszentren sind innovative High-End
Lösungen. Prozessoptimierung, Präzision, Qualität und
Zuverlässigkeit stehen für Produktivität und Flexibilität.
ALUMINIUM · 9/2013

ALUMINIUM INDUSTRY IN THE GULF
Interview with Emal president and CEO, Saeed Fadhel Al Mazrooei
“We can compete with any company in the world”
© Emal
President and CEO Saeed Fadhel Al Mazrooei:
“Emal has a strong global market demand, and the
local market and the downstream industry in the
UAE are also growing.”
ALUMINIUM’s editor-in-chief recently had
the opportunity to visit Emirates Aluminium
(Emal) in Abu Dhabi and talk to president
and CEO, Saeed Fadhel Al Mazrooei, about
the company’s future development, its Phase
II expansion project, the Arab Aluminium
Conference 2013 in Abu Dhabi in November,
which will be hosted by Emal, and the
recent announcement of the unification taking
place between Emal and Dubal. Emal is currently
expanding its production capacity from
800,000 to 1.3 million tonnes of aluminium
and construction work at the site is in full
swing. Once Phase II has been commissioned,
Emal will be one of the largest single-site aluminium
smelter in the world.
ALUMINIUM: Mr Al Mazrooei, the Emal site
and technical facilities are really impressive
compared with the relatively small European
smelters. There is a lot of construction work
underway for the Phase II expansion. Is everything
on schedule?
Al Mazrooei: Yes, Phase II will be completed
on schedule, and within budget. We will start
energising the first cell early in the fourth
quarter of this year. First hot metal will be
produced at year-end, with full production
being reached around mid-2014. Then we
will not only have the longest potline in the
world – 1.7 kilometres long – but also the best
smelter technology available today.
ALUMINIUM: … the DX+ technology from
Dubai Aluminium.
Al Mazrooei: The DX+ technology is a further
development of the DX technology and will
be used in our Phase II potline. Our Phase I
potline uses the DX technology, now at 380
kA, upgraded from the 350 kA previously.
This upgrade has boosted our aluminium production
from 750,000 to 800,000 tonnes a
year. The DX+ cells of the potline under construction
will initially operate at 440 kA, and
have the potential to operate at 460 kA. For
that we have ordered the world’s largest rectifier
ever being built. The current efficiency of
the DX+ potline will be the benchmark for
the rest of the industry.
ALUMINIUM: Emal is already one of the most
cost-efficient smelters in the world thanks to
the low cost of natural gas from Abu Dhabi.
This low-cost situation will improve further
when the third potline comes on stream.
Al Mazrooei: There are three main criteria for
our outstanding position. One is energy, ‘clean
energy’ as we call it. The second is the DX
technology we use. It is the latest technology
and has been developed to produce metal in
a highly energy-efficient manner. And thirdly
we should mention that we have implemented
processes and procedures in our plant that
promotes high productivity of our workforce.
ALUMINIUM: The third potline will boost
production to 1.3 million tonnes a year. Most
of your production is destined for export.
Where do you sell your products?
Al Mazrooei: Today our products are sold to
over 150 customers in almost 36 countries
worldwide. 80 percent of our products are
delivered to Asia, the US and Europe. About
Emal potline, based on Dubal technology
30 percent of our products are delivered to
South Asia, for example to Korea and Japan.
We sell almost 200,000 tonnes a year to the
US. We also sell our products to Europe, with
Germany our largest market there. The Middle
East takes part of the volumes, as do local
markets in the Gulf. Our products are ISO
9001 certified so we comply fully with international
standards.
ALUMINIUM: The Middle East and Asia are
on your doorstep whereas the United States
and Europe are farther away. Does distance
to market hinder your business in any way?
Al Mazrooei: We are located in the middle of
the world so we are able to deliver to Europe
without any problems. The same applies to the
US.
ALUMINIUM: There are still EU customs duties
on imports of aluminium to protect the
European smelters. These must be a thorn in
your flesh.
Al Mazrooei (laughing): EU competitors are
trying to protect their business but I think it is
necessary to look at the industry as a whole.
Downstream manufacturers should benefit
from access to international markets. The European
smelters were built many years ago
and do not have the best energy efficiency.
I think the European aluminium industry
should encourage the downstream business
because that is where the real added value is
to be found. The same companies that push for
EU customs duties come to the UAE and build
new production facilities, albeit targeting the
Asian rather than the European market. ➝
26 ALUMINIUM · 9/2013

SPECIAL ARABAL
ALUMINIUM INDUSTRY IN THE GULF
IS YOUR COMPANY BENEFITING
FROM ACCESS TO MOLTEN
ALUMINIUM AND RELIABLE
LOW COST UTILITIES?
KHALIFA INDUSTRIAL ZONE ABU DHABI
_ RELIABLE, LOW COST UTILITIES FOR LESS THAN
$0.04 PER kWh
_ INTEGRATED WITH KHALIFA PORT, SUPPORTED BY WORLD
CLASS INFRASTRUCTURE
_ 0% TAX ENVIRONMENT AND CUSTOMS DUTIES EXEMPTIONS
_ FREE ZONE AND NON FREE ZONE BUSINESS SETUP OPTIONS
WITH 100% OWNERSHIP OPPORTUNITIES
GIVE YOUR BUSINESS THE ADVANTAGE
LET’S TALK
+971 800 10 20 30 | kizad.com
an ADPC company

ALUMINIUM INDUSTRY IN THE GULF
Business between the Gulf and Europe is built
on long-term relationships and the aluminium
business should be based on that concept too.
A free trade agreement should really be considered
where the most efficient competitors
survive and the most economical and environmentally-friendly
businesses flourish.
ALUMINIUM (provoking): Would you dare
to make a prediction when the last aluminium
smelter will be shut down in Europe?
Al Mazrooei (again smiling): If I could see into
the future I wouldn’t be sitting here. But to be
serious: in the end it all depends on economics,
on the cost of producing aluminium. And
there are many cost drivers for European
smelters such as electricity tariffs, taxation
and environmental costs. But business models
have to survive too. You need a business that
is sustainable. That is what the Gulf is doing
today. Here you find competitive energy prices,
the most modern production technology
and state-of-the-art equipment for environmental
protection; this allows the Gulf smelters
to produce on a more efficient basis.
ALUMINIUM: The conditions are ideal for
you to expand beyond your current project.
When I toured the site an hour ago I saw that
there is space for a Phase III potline.
Al Mazrooei: We have space to grow but every
new investment must be built on a strong business
case. When Emal seeks finance, it does
not go to the governments of Abu Dhabi or
Dubai but to the international financial markets.
Therefore the business model has to be
structurally strong to convince long-term investors
to commit themselves financially. We
have to justify our business model and to look
20 to 25 years down the road. A Phase III expansion
is an option, but at present we are focused
on the start-up of our Phase II project.
ALUMINIUM: Finance is one thing, but the
market conditions have to be right too. Looking
at the present market situation we see a
lot of overcapacity, imbalance in supply and
demand, with rather weak aluminium prices.
Is that the right time to expand?
Al Mazrooei: That’s the general market you
describe. However, when I look at our books
there is no reason to complain. Demand for
our products is greater than what we can deliver.
Last year, demand for our products was
around one million tonnes whereas our plant
can only produce 800,000 tonnes a year. We
are doing well on market penetration. We are
market-driven and customer-focused. And
from a capex point of view, today is the best
time to build a new smelter because investment
costs are low. At a time of market stagnation
it is easier to find the money for well justified
investment projects. And there is good reason
that the market imbalances will diminish
In April Emal was celebrating 25 million hours worked without a single lost time incident
over the coming years. But again, we are fully
booked and will be producing at full capacity.
Furthermore, although the LME price for aluminium
is rather low at present, premiums are
high and offset the weak aluminium price.
ALUMINIUM: Are you confident you will be
able to sell the additional volumes from the
third potline right away?
Al Mazrooei: I don’t think there is an issue
for selling. Emal has a strong global market
demand, and the local market and the downstream
industry in the UAE are also growing.
There are already five potential downstream
companies planning to operate in the UAE
and one is under construction today at Al
Taweelah in Kizad, the Khalifa Industrial
Zone – Abu Dhabi, and will come on stream
soon.
ALUMINIUM: You refer to the Al Taweelah
Aluminium Extrusion Company…
Al Mazrooei: … That will be the starting point
of the so-called ‘hot metal road’ between Emal
and downstream companies to deliver molten
aluminium at further reduced costs and environmental
impacts. It will encourage other
manufacturing companies to settle in Kizad.
Most of the production will go into building
and construction but there is a multitude of
target markets.
ALUMINIUM: Do you expect the automotive
industry to settle here too?
Al Mazrooei: Not yet. That might happen
later. The manufacturing of aluminium wheels
and other high-value niche products could
be an approach in addition to cable, wire and
rod. But most of the production will be for
export.
ALUMINIUM: Health, safety and environment
protection are of great importance to
Emal. That applies to other companies too, but
from what I’ve read your records are particularly
impressive.
Al Mazrooei: Yes, we are proud of our records
in these fields. Take safety, for an example.
Today, early in July, we are looking at 35 million
work hours without an accident on the
Phase II construction site. That is a record for
the industry. We are looking at more than 15
million work hours without a lost-time incident
in our operations during the last three
years. We do a lot to take care of our employees.
For example, just this morning we
had a crew member meeting where all the
staff, 12,000 project workers, was assembled
to be informed about the symptoms and risks
of dehydration and how to protect against it.
We encourage our employees to take care of
each other and to be aware of the emergency
numbers you can call in case your colleague
suffers from dehydration. We take care that
our employees are conscious of risks at the
workplace. Every new employee undergoes
safety induction. We reward them when they
do things properly and safely. Then we give
them a token; three tokens will give them
some credits they can trade in for money. I
could list similar success items when it comes
to environment protection. We have spent a
good deal of money – more than 700 million
US dollars for Phase I – in environment-related
equipment to minimise our emissions
and to monitor them.
ALUMINIUM: Do you have also a continuous
improvement programme?
Al Mazrooei: We have a suggestion scheme
that allows workers to make any kind of proposal
that is related to the production process
or to safety at work. The suggestions go to a
committee to check if it is worth being implemented
or not. Our employees get a reward
for making the suggestion, and get rewarded
when it is implemented. Up to date we have
had more than 12,000 suggestions with more
28 ALUMINIUM · 9/2013

ALUMINIUM INDUSTRY IN THE GULF
than half of them implemented. Our motto is:
Everything can be improved.
ALUMINIUM: There was recent announcement
by your parent company Mubadala that
it is going to merge the businesses of Dubal and
Emal to create Emirates Global Aluminium.
What is the reason behind this decision?
Al Mazrooei: Although Dubal and Emal
have been separate companies, we have always
worked closely together on different
platforms, for example on technology, logistics
and material supply. We rely on Dubal
to procure all our materials and utilise their
experience in sales and marketing. When we
started the production of Phase I in 2009 our
employees were trained at Dubal. So there is
a lot of Dubal culture embedded at Emal. The
only difference was in the ownership, which
has now changed. Mubadala owns fifty percent
of both Dubal and Emal. Dubal, which previously
owned fifty percent of Emal, transferred
its ownership in Emal to ICD, a Dubai Government
investment fund that owns the other
half of Dubal. In principle, there will not be
much of an operational change. It is mainly
the ownership that has changed.
ALUMINIUM: Does that mean Emirates
Global Aluminium is a kind of holding company?
Al Mazrooei: It is a corporation that will look
after many types of operation. For example,
Mubadala and Dubal have stakes in projects
in Guinea and elsewhere. Dubal has a stake
in a calciner project in China for the manufacture
of carbon anodes. There is a feasibility
study underway for an alumina refinery at Al
Taweelah. In other words: Emirates Global
Aluminium will have a much bigger business
perspective than Emal on its own.
ALUMINIUM: What about the brand names
‘Emal’ and ‘Dubal’ as references for high-quality
aluminium? Will these brands be replaced
by a brand name like ‘Emirates Aluminium’?
Al Mazrooei: We have worked hard to establish
‘Emal’ as a brand. Dubal too has its
own highly renowned brand backed by thirty
years’ effort to establish a strong position in
the market. It wouldn’t be wise to give up this
goodwill. In future, we will operate under the
same umbrella with two smelters at different
sites. There will be one sales team, but for two
different products – Dubal and Emal.
ALUMINIUM: Has this integration already
started or will that be implemented at a later
date?
Al Mazrooei: We are still waiting for endorsements
from regulatory authorities in all regions
where we sell our products. We hope to have
all approvals in place by the end of the first
quarter of 2014.
Emal has spent more than USD700m in environment-related equipment to minimise emissions from
aluminium production
ALUMINIUM: I understand you will become
CEO of UAE operations.
Al Mazrooei: Both for the operations at Emal
and Dubal and for any future UAE Project. Mr
Abdulla Kalban, formerly president and CEO
of Dubal, will be the MD and the CEO of Emirates
Global Aluminium and in charge of UAE
and global operations.
ALUMINIUM: Do you regard this merger as
a big opportunity to grow?
Al Mazrooei: Yes, that is the goal – to grow,
not to shrink, and to realise synergies while we
grow. If you look at mergers in Europe or elsewhere,
they are mostly executed in order to
reduce overhead and cut costs. Our approach
is the other way round. Nobody will lose his
job, people will maintain their present work
but there will be synergies for the system and
procedures.
ALUMINIUM: Emal is hosting the Arabal
Conference in November in Abu Dhabi? What
is the principal idea behind this conference?
Al Mazrooei: To bring people from the global
aluminium industry together. To promote
the UAE as an attractive location for industry
in general and especially for the aluminium
industry. To show potential investors where
we stand today and what we can offer. There
are many opportunities in the Gulf and the
UAE for starting up businesses. As you know,
when doing business you have to look at your
competitors, at the markets and technologies,
and where the business is going to develop.
We are looking forward to many company
representatives participating in the event. We
are targeting particular companies that we
want to be part of the conference. There will
be a good balance of presentations and time
for networking. And of course, part of the
programme will be workshops and a site tour
for all visitors that are interested in getting an
impression of our smelter.
ALUMINIUM: So you are not only expecting
attendees from the primary aluminium industry,
but from the industry as a whole and from
all over the world?
Al Mazrooei: Yes, from the upstream and
downstream sectors, from suppliers and customers,
bankers and investors. We want to
bring industry experts and decision makers –
politicians and senior executives – to Arabal.
We are very proud to host this conference and
are working hard to make it a unique event –
in terms of the material that is presented, the
people that will be attending and the speakers.
The conference will start two days after another
exciting event in Abu Dhabi: the Formula
1 Grand Prix. That will be a good opportunity
to combine business with pleasure.
ALUMINIUM: A final word about Emal’s
market position: do you see Emal as one of
the top three smelters in the world?
Al Mazrooei: Not only as one of the top three,
but as No 1: not in terms of volumes, but the
different platforms we have just talked about.
We are No 1 on start-up commissioning and
ramp-up; nobody has broken our record yet.
We are No 1 in project execution: we have the
lowest capex per tonne of aluminium. We are
No 1 in safety record: we recently won a safety
award from the RoSPA, the Royal Society for
the Prevention of Accidents. I am proud to say
that we can compete with any industry and
aluminium company in the world.
ALUMINIUM: Mr Al Mazrooei, many thanks
for this discussion.
■
30 ALUMINIUM · 9/2013

What about the compliance of your Anode Baking Furnace?
Qatalum selected Fives Solios’ solutions for its Anode Baking Furnace
to comply with the highest standards in terms of safety and emissions
Qatalum is operating one of the most efficient and most environmentallyfriendly
aluminium smelters in the world.
By implementing the best available technology in terms of Firing & Control
Systems and Fume Treatment Centers on the Anode Baking Furnaces, Qatalum
ensures that the operation of its furnaces is safe and that the stack emissions
of condensed and volatile tars, dust and hydrogen fluoride are kept under
the most stringent environmental levels.
Thanks to its long experience both in Firing & Control Systems and Fume Treatment
Centers, Fives Solios offers additional synergies as part of an integrated FCS/FTC
design to further improve emissions, OPEX, working and safety conditions
for a more reliable Anode Baking Furnace.
Fives Solios, designing today the plants of the future
www.fivesgroup.com
Driving progress

ALUMINIUM INDUSTRY IN THE GULF
17 th Arab International Aluminium Conference 2013
Arabal is the premier trade event for the
aluminium industry in the Middle East,
and the only conference in the world attended
by every single primary aluminium
manufacturer in the region.
The story began in 1983 with Kuwait Aluminium
Co. bringing together the leading figures
in Middle East Aluminium to strengthen ties
and discuss the issues of the day to provide an
overview about the entire aluminium industry.
Over the past three decades, the Arabal Conference
has grown to attract heads of industry
from around the world to attend, speak, and
exhibit, and by 2011 Arabal attracted more
than 450 delegates.
Since its foundation, and until 2009, the
conference has been hosted in a different
country in the Middle East region bi-annually.
As of the 2010 conference in Oman, due to
the impact and significant role of Arabal, the
steering committee agreed to hold the conference
on an annual basis. This year, the conference
is hosted by Emirates Aluminium. International
ALUMINIUM Journal is the official
media partner of the conference.
Confirmed speakers
Arabal 2013 is proud to confirm the following
speakers, who will be participating at this
year’s event: H. E. Juma Mohammed Ahmed
Al Kait, Assistant Undersecretary for Foreign
Trade Affairs, Ministry of Economy. Mohammed
Al Naki, Chairman of Arabal. Tim Murray,
CEO of Alba. Khalid Abdulla Al-Luhaidan,
Vice President, Aluminum SBU, Ma’aden.
Yousuf Bastaki, Vice President EHSSQ, Emal.
Ali Al Zarouni, Vice President, Smelting Operations,
Dubal. Vladislav Soloviev, First
Deputy CEO of Rusal. Kamil Wlazly, Senior
Metal Analyst, Metals Bulletin. Marco Georgiou,
Head of Aluminium Primary and Products,
CRU Group. Edgardo Gelsomino, Senior
Analyst at Wood Mackenzie. David Wilson,
Director, Metals Research and Strategy, Citi
Research. Walid Al Attar, VP Marketing and
Sales, Emal and Dubal. Joe Lombard, Group
Managing Director, Hatch. Mudar Al Mekdad,
General Manager, Gulf Extrusions Co. LLC.
Hamid Al Zayani, Managing Director, Midal
Cables. Khaled Salmeen, CEO and Managing
Director, Kizad. Diran Apelian, Alcoa-
Howmet Professor, Mechanical Engineering,
Worcester Polytechnic Institute. Nick Madden,
Senior Vice President and Chief Procurement
Officer, Novelis Inc.
■
ARABAL CONFERENCE 2013 – Provisional agenda
Tuesday, 5 November 2013
10:00 Pre-conference workshop
Dubai Aluminium (Dubai)
12:00 Lunch
14:00 Site tour to the Emal smelter complex
18:00 Registration
19:00 Welcome reception
Wednesday, 6 November 2013
8:30 Opening address:
The Patron; Arabal host; Emal host
9:00 Session 1
The Global economy and its challenges
Economic overview of GCC; European and global
marketplace; featuring HE Jumaa Al Kait and his
views on the European and GCC relationship
Moderator: Mahmood Al Daylami, secretary
general Gulf Aluminium Council
10:30 Coffee break
11:00 Session 2
GCC smelters – opportunities, investments and
future plans
Panel discussion with representatives from Emal,
Dubal, Qatalum, Maaden, Sohar and Alba
Moderator: Raju Daswani, Metal Bulletin
13:00 Lunch
14:30 Session 3
Warehousing, financing deals and future of
metal exchanges
Warehousing rules and the impact on aluminium
inventory; featuring first deputy chief executive of Rusal
15:30 Coffee break
16:00 Session 4
Aluminium market price outlook
Panel discussion with industry pricing analysts from MB,
CRU, Wood Mackenzie and Citi Research
Moderator: Zaid Aljanabi, senior industry analyst, Emal
17:15 End of Day
18:30 Transportation to gala dinner premises
19:00 Reception, followed by gala dinner
Thursday, 7 November 2013
9:00 Session 5
Casthouse product mix and downstream initiatives
in the Mena region
Presentation by VP Marketing and Sales of Emal,
Dubal and GMD of Hatch
10:00 Coffee break
10:30 Session 5 continued
Casthouse product mix ...
Presentations on successfully established downstream
projects and on the industrial infrastructure in the
Mena region
12:00 Lunch
13:30 Session 6
Environmental drivers
Presentations on R&D for aluminium products in the
GCC and the future of recycling for the aluminium
industry in the Middle East
14:15 Coffee Break
14:45 Session Six continued
Environmental drivers
Featuring presentations on the GCC smelters, the best
supply partners for future generations and clean
energy supplies to the aluminium sector
15:15 Closing speech
32 ALUMINIUM · 9/2013

ALUMINIUM INDUSTRY IN THE GULF
Best technology for the aluminium rolling industry in the Gulf
B. Rieth, Meerbusch
The aluminium industry in the GCC
countries has for many years achieved
impressive growth. Whereas in 2000
the production of primary aluminium
amounted to around one million tonnes,
today it has already reached 3.7 times as
much. From 2015 when the new Ma’aden
smelter in Saudi Arabia and the third
potline of Emal in the UAE will come
into production, the region will have
capacities of almost five million tonnes a
year. In contrast, no such dynamics can
be seen where the further processing of
aluminium into semis is concerned. Here,
growth has until now been governed by
need. However, a new impetus has been
provided by the objective of no longer
just converting the available oil and
gas ‘into solid form’ as aluminium, but
achieving at least some value addition in
the region by virtue of further processing,
for example to make rolled products.
Until now the aluminium semis industry in
the Gulf region has been developing at various
rates. Whereas the building boom of previous
years encouraged the creation of numerous
extrusion plants since the 1990s, other
aluminium semis and finished products were
previously produced only by a few plants.
Among others this applies to rolled products,
of which the GCC countries have always been
a net importer until now.
Aluminium flat products have until now
been produced in the region only by Gulf
Aluminium Rolling Mill (Garmco) in Bahrain.
That plant was set up in 1981 as part of the
aluminium cluster around the smelter of Aluminium
Bahrain (Alba). Garmco operates hot,
cold and foil rolling mills which have repeatedly
been modernised and brought up to the
latest state of the art. They produce cold rolled
coils and sheet in 1xxx, 3xxx, 5xxx and 8xxx
series alloys for a wide range of applications,
from food containers and stylish up-market
hollow-ware to high-profile architecture and
paint industry in gauges from 0.25 to 3.2 mm
and up to 1,560 mm wide.
From next year onwards there will be two
more major aluminium rolling mills in the
region, which will steadily boost the quantity
produced over the coming years from its
present level of around 200,000 tonnes up to
about one million tonnes a year.
A new supplier of aluminium flat products
is arising with Oman Aluminium Rolling
Company, LLC (OARC). This company,
100%-owned by Takamul Investment Co., is
currently commissioning a USD387 million
aluminium strip-rolling plant with a production
capacity of 160,000 tonnes a year. The
main supplier is Fata EPC in Italy, which is also
acting as the general contractor.
OARC will be the largest purchaser of molten
aluminium from the neighbouring Sohar
Aluminium smelter.
The plant is designed for the production
of strips made from alloys of the 1xxx, 3xxx
and 8xxx series, in widths up to 1,950 mm
and in the thickness range of 0.075 to 1.5 mm
in the form of semi-finished coil products,
i.e. foil stock for converter and packaging foil,
and cable wrap. In addition it will produce
finished coil products such as semi-rigid container
foil, for example for aluminium food
containers and fin stock for the air conditioning
and automotive heat exchanger markets.
Further products planned will be tension-levelled
industrial sheet for building products in
the thickness range 0.3 to 1.5 mm.
The concept of the plant is worthy of particular
attention. The capacity of 160,000
tonnes a year is lower than the economically
viable limit of a conventional plant consisting
of a rolling slab casting unit and hot and cold
rolling mills, but relatively high for the alternative
possible use of twin roll casting machines.
Accordingly a different solution was
decided upon: the molten aluminium will be
delivered via holding furnaces to a twin-belt
caster and solidified into strips 2,032 mm wide
and 13 to 21 mm thick.
The solidified strip will go directly to a hot
mill where it will be reduced down to a thickness
of 1 to 2 mm in an in-line hot rolling
process, and then coiled. This will then be followed
by the usual cold-rolling process on a
four-high reversing rolling stand with the necessary
intermediate and final annealing operations.
The capacity of such an in-line hot rolling
unit, for a cast width of 2,000 mm, certainly
amounts to 250,000 to 300,000 tonnes a year.
This means that when the cold rolling and finishing
capacities are increased accordingly, the
plant can be adapted for future market developments
with relatively little effort and costs.
Specialised slitting and coil coating operations
are provided in the finishing area.
Major project in Saudi Arabia
A further aluminium rolling mill is at present
being built as the first construction stage of
an integrated mining, smelter and rolling complex
together with the aluminium smelter in
Saudi Arabia’s Ras Az Zawr at the northern
end of the Arabian Gulf. There, at present the
US producer Alcoa Inc. and the Saudi Arabian
mine operator Ma’aden (Saudi Arabian
Mining Company) are together implementing
an ambitious smelter project as a joint venture,
Ma’aden-Alcoa. The aluminium smelter
built as the first stage celebrated in December
2012 the successful commissioning of the
first of 720 smelting pots – a key step towards
commercial production at the smelter.
© Fata
Hazelett caster from Fata Hunter…
… and cold rolling mill for OARC
34 ALUMINIUM · 9/2013

SPECIAL ARABAL
ALUMINIUM INDUSTRY IN THE GULF
The hot-rolling mill will be fed with rolling
slabs, for the production of which Wagstaff
Inc., USA, will supply cutting-edge ingot and
billet casting systems with integrated automated
controls, which have been shown to deliver
improved recovery rates as well as higher
levels of workplace convenience and safety.
The casting facility will also feature Alcoa’s
advanced proprietary ingot casting technology
which provides rolling ingots with a highly improved
surface finish with consequential gains
in rolling efficiency and product quality.
The rolling slabs will be heated in two pusher-type
furnaces from Ebner Industrieofenbau,
Austria. The two ‘Hicon’ pusher furnaces
each hold 30 aluminium rolling slabs of maximum
dimensions 635 x 2,100 x 9,000 mm.
Besides the tried and tested Ebner-specific
Hicon plant components, which are decisively
necessary in order to achieve great temperature
uniformity in the slabs and high energy
efficiency, the most up-to-date process control
has been called for. In that context the twodimensional
temperature computation model
TREATperfect developed by Ebner suits the
purpose admirably. In this, each rolling slab
is computationally divided into individual elements.
Within these elements the heat transfer
in a particular time frame are determined
mathematically.
Throughout the annealing process TREATperfect
compares the pre-calculated temperature
variations with those actually taking
place, and can therefore react to perturbations
or changes of circumstances and adapt
the planned annealing time.
Besides the furnaces, the equipment supplied
by Ebner includes the complete slab handling
system, from slab reception to transfer
of the heat-treated slab onto the roller track
of the hot mill.
The integrated rolling complex, currently
being assembled, consists of a hot-rolling mill
with capacity 650,000 tonnes a year and two
cold-rolling mills. The first cold mill, with a
capacity of 400,000 tonnes of aluminium strip,
serves to produce food-grade can stock which
has many applications including the manufacture
of beverage cans. The second cold mill
has a capacity of more than 150,000 tonnes
and mainly produces high-grade strip for
the automobile industry. The new plant will
not just boost the creation of a local further
processing industry. Thanks to its geo-strategically
favourable position the investors surely
also have their sights on growth markets for
aluminium flat products which are capable of
development, e. g. in the Middle East.
The main supplier of the complete integrated
hot and cold rolling plant, including its electric
and automation systems, is SMS Siemag.
For the hot-rolling plant SMS Siemag is
supplying the complete 1 + 4 pre-rolling and
finishing line. The pre-rolling section consists
of a quarto preliminary stand which rolls down
the in-coming aluminium slabs up to 635 mm
thick and weighing up to 32.5 tonnes. The
preliminary line also includes a heavy and
light hydraulic cropping shear for intermediate
cropping and for removing the leading and
trailing ends of the preliminary strip.
The quarto-designed four-stand hot finishing
line rolls the preliminary strip coming in
with a thickness of about 30 mm, down to
final thickness of 2 to 7 mm in a single pass.
In the run-out area of the finishing line the
finished strip is trimmed and taken up by a
hot-strip spool with belt wrapper.
After the hot mill the plant has two coldrolling
lines, designed for the production of
various strip qualities.
➝

ALUMINIUM INDUSTRY IN THE GULF
© SMS Siemag
3D layout of the SMS Siemag aluminium cold rolling mill…
The first plant, with a rolling capacity of more
than 400,000 tonnes a year, produces mainly
can stock. For this, SMS Siemag is supplying
the complete cold mill and coil preparation
station in the run-in area and an off-line strip
inspection facility in the run-out area. The efficient,
four-stand tandem line of quarto design
rolls the in-coming aluminium hot-rolled strip
up to 2,100 mm wide down to a minimum
final thickness of 0.15 mm. The tandem line
is equipped with tried and tested control elements
such as hydraulic positioning, positive
and negative working-roll bending and CVCplus
technology. The control systems ensure
optimum strip flatness,
strip thickness tolerances
and a perfect strip
surface.
The hot mill and
tandem cold mill are
equipped with all the
control and regulation
systems needed to ensure
reliable process
management of the
fully automatic rolling
process. For this Alu-
Control is used, an automation
system matched
to the process requirements
of aluminium rolling, which is part of
the ‘X-Pact’ electric and automation system
of SMS Siemag. In both plants Alu-Control
covers the levels from Level 0 to Level 2.
After leaving the cold tandem line the coils
go on to a fully automatic coil-coating line
supplied by BWG Bergwerk- und Walzwerk
Maschinenbau GmbH in Germany.
In addition to the clearing and coating sections
this has a drying oven which, like the
complete electric and automation systems of
the plant, is also included in the BWG technology
package. The line is designed in accordance
with the most up-to-date specifications
as implemented many times over in similar
units recently supplied by BWG to other Alcoa
companies.
A second cold rolling mill will enable the
Ma’aden Alcoa joint venture to include capability
for producing about 150,000 tonnes of
a wide range of products suitable for further
downstream manufacturing in the complex’s
product lines. They include automotive heattreated
and non-heat-treated sheet, building
and construction sheet and foil stock sheet.
An order has been released to SMS Siemag
for the supply of the mill equipment and heat
treatment line. “These new capabilities will
help establish downstream industries in Saudi
Arabia using aluminium that has been mined,
refined, smelted and rolled in the Kingdom.
It is also fully compatible with the national
strategy of developing national resources to
create sustainable wealth and employment
… and annealing and coating line for Ma’aden
for Saudis, as well as enabling
the replacement of
a wide range of imports
with cost-effective, highquality
domestic products,
and encouraging the
expansion of the national
industrial base,” says Khalid
Mudaifer, Ma’aden’s
president and CEO.
The order for SMS
Siemag comprises a single-stand
cold-rolling mill
with an annealing and
coating line that is especially
suitable for automotive
grades of aluminium.
Feedstock for the new
plant will be coils up to
2,100 mm wide and weighing
30 tonnes and these will be supplied from
the hot-rolling mill of the first phase.
The new line will be equipped with a 4-
high rolling stand with CVC plus, working roll
bending, multi-zone coiling and a dry-strip
system in order to meet the requirements for
the automotive grades of aluminium to be
rolled. An annealing and coating line with an
annual production capacity of 50,000 tonnes
of 5000 and 6000 series alloys will adjoin
the cold-rolling mill. Cold-rolled strip up to
2,100 mm wide in the thickness range 0.8
to 3.5 mm will be annealed and coated in a
continuous process. This line is built in collaboration
between the Strip Processing Lines
and Thermal Process Technology divisions of
SMS Siemag.
One of the core elements is the GATV
floater furnace with high-performance water
quenching. Uniform mechanical properties
such as a grain size and hardness will be
obtained in a reproducible manner over the
whole length and width of the strip. High
cooling rates immediately after stress reliev-
36 ALUMINIUM · 9/2013

SPECIAL ARABAL
ALUMINIUM INDUSTRY IN THE GULF
ing are one of the prerequisites
for producing the quality
demanded by the automotive
industry. To achieve these,
the unit will be equipped with
a high-performance air-cooling
facility and water cooling.
Besides continuousthroughput
strip treatment
Ma’aden-Alcoa will also be
able to heat treat single strip
coils individually. This unit is
particularly suitable for being
able to fulfil annealing
contracts flexibly and costeffectively
with a demonstrably controlled
heat treatment, as is often called for by the
automobile industry. To achieve that objective
Ma’aden-Alcoa has ordered from Tenova
LOI Thermprocess in Germany a complete
line of single-coil lifting hearth furnaces. A
number of individually loaded and operated
furnace chambers together form a furnace
battery. The overhead arrangement enables
space-saving charging by an automotive transport
system, from below.
This line allows adapted heat treatment according
to the specific needs of the individual
strip within a short time, instead of heat treatment
in batches of several coils, which would
require an average heat treatment or the assembling
of a batch of identical strip coils.
The heat treatment including cooling can be
carried out under a protective atmosphere.
The system works fully automatically from
taking the coil out of the storage area until
the heat treated coil is placed into the storage
area again.
Tenova LOI Thermprocess was the first to
invent and design this type of furnace. The
first unit was installed in 1998 by Constellium
(formerly Alcan) in Singen, Germany, for automotive
sheet applications. By now the company
has built 68 such single-coil lifting hearth
furnaces in batteries up to 17 units.
Before the rolled, heat-treated and surfacetreated
coils are sent for dispatch, they must
again be trimmed and cut to the dimensions
specified. Danieli Fröhling in Germany, one
of the noted suppliers for aluminium coldrolling
mills and a market leader for aluminium
cutting machinery, already supplied for
the first cold mill two technologically sophisticated
cutting units and two associated packaging
machines. These units are designed for the
strictest quality and quantity demands.
For the second cold mill the company is
also supplying a longitudinal slitting machine
with downstream packaging of the finished
coil, specially designed for automotive needs.
The plant’s structure and special features relating
to strip movement and equipment were
developed in close collaboration with the end
customers, in order to satisfy all the special
customer requirements. This process was
greatly influenced by the wealth of experience
gained by both Alcoa and Fröhling from
previous projects.
The plant includes the complete range of
equipment supplied, beginning from the runin
side: the conditioning machine for reducing
the coil-set, inline strip preparation by means
of drum shears, the
cutting zone with
CNC shear and
exchange station,
the strip braking
zone and the electrostatic
oiling unit,
as far as coil winding
and transfer to
the packaging unit.
Within the downstream
packaging
unit, depending on
the programme the
coils are isolated,
weighed, packed in
foil and stacked on
pallets. The work
steps throughout
the plant take place
automatically, with
attention paid to
maximum efficiency
in the design of
each unit.
The completion
of the new plant
is anticipated with
great attention not
only in Saudi Arabia.
“The rolling
mill will be a significant
milestone
Danieli Fröhling line for Ma’aden from run-in side to packaging
in the development of the first fully integrated
aluminium complex,” says Ken Wisnoski,
president of Alcoa’s Global Primary Products
Growth business.
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.
Molten Metal Level Control
© Danieli Fröhling
ALUMINIUM · 9/2013 37

ALUMINIUM INdUstry IN the GULf
Kizad aluminium cluster taking shape
B. rieth, Meerbusch
A large part of the Emirate of Abu
Dhabi’s 2030 economic vision is based on
diversification of the economy. Several
ambitious projects have been initiated
in the emirate to broaden and diversify
its economic base. The Khalifa Industrial
Zone Abu Dhabi, or Kizad as it is better
known, is aimed at establishing an additional
source of economic activity in
the form of light and heavy industries together
with related trading and services.
The emirate wants to attract not only
domestic investors, but also top-class foreign
companies wishing to locate there.
By developing Kizad, the emirate is also
aiming at providing suitable employment
for its growing workforce of young and
well-educated nationals as well as attracting
experts from other countries to work
in the Gulf region.
Aerial view of midstream aluminium industries with Hot Metal Road
Khalifa Port, a modern deepwater port that
has been fully operational since September
2012, is a major asset to the investors in Kizad;
designed and owned by Abu Dhabi Ports Company
(ADPC), it is the only semi-automated
port in the region. Kizad covers an area of over
417 square kilometres, split between Area A
and B, and includes several sector-oriented industry
clusters as well as residential and commercial
areas. Besides having direct access to
the port, Kizad is linked to the Abu Dhabi to
Dubai highway, thus to the whole of the Gulf
region’s road network. Three international
airports, Abu Dhabi, Al Maktoum and Dubai,
can be reached quickly via this network. An
impressive rail link is also currently under
construction through Etihad Rail, that will see
lines eventually running from Khalifa Port
to several trade links throughout the region.
Thanks to Kizad’s outstanding geo-strategic
location, goods produced at this industrial
zone can be shipped quickly and cheaply to
the growing markets of the Arabian Peninsula,
Western Europe, Africa and East Asia where
over 4.5 billion people are less than four time
zones away.
The planned industry clusters are vertically
integrated and organised according to industry
sectors. An anchor tenant will produce
the necessary raw materials, which will be
supplied to downstream processors in the
respective value chain. This added value will
not only be created during production of the
basic materials, such as aluminium, but also
along the whole value chain.
Today Kizad caters to the following industrial
clusters: aluminium, steel, engineered metals,
glass, paper, print and packaging, trade and
logistics, as well as mixed uses such as petrochemicals,
chemicals and plastics, construction
and building materials, pharmaceuticals and
© Kizad
medical products, high-tech and clean tech,
and food processing.
Besides the purely vertical integration
within the individual clusters, it is also conceivable
that there will be synergies between
the clusters. For example, aluminium foil from
the aluminium cluster might be used by converters
from the pharmaceuticals, food and
packaging clusters.
efficiency through vertical integration
The aluminium cluster is a graphic example of
Kizad’s innovative implementation of its vertical
clustering concept. Plans were made at an
early stage to establish aluminium processing
plants locally and thus increase the added value
generated locally to ensure that the cheaply
produced aluminium is not merely exported in
the form of ’solidified energy’. The first successes
are already tangible. Companies focusing
on finished aluminium products for local
and regional markets are moving to locate
here, partially as a result of the high level of
imports of such products in the Gulf region.
However, the primary attraction for producing
finished aluminium products in the Gulf
region and supplying the world market will
be cost benefits for energy and labour coupled
with the extensive facilitation of investments
for foreign investors.
At the centre is Emal, Emirates Aluminium,
with one of the most advanced aluminium
smelters in the world. Emal is the anchor
tenant for Kizad’s aluminium cluster. Its most
modern aluminium smelter has a capacity
of 800,000 tonnes a year and has been on
stream since 2010. At the end of 2011, the
company announced that it had created 2,000
new jobs. Emal supplies its products – sows,
standard ingots, sheet ingots and extrusion billets
– primarily to Europe, the USA and Asia.
The site includes a 2,000 MW power plant, a
carbon plant and a casthouse. Raw materials
are transported directly from the sea to the
smelter via an exclusive purpose-built wharf
at Khalifa Port.
The production capacity is currently being
expanded to 1.3 million tonnes a year with
full production is expected by mid-2014. This
will make Emal the fifth largest aluminium
producer in the world.
A special feature of the aluminium cluster,
referred to in Kizad as the Hot Metal Road,
is a unique and innovative supply route for
38 ALUMINIUM · 9/2013

“Wouldn‘t it be great
if we could get our
plant back to working
temperature in less time?”
“Sure – no problem!”
www.refra.com
Faster plant availability thanks to intelligent refractory technology?
Perfectly feasible. For example by using mixes based on our
pioneering cement-free Nanobond binder technology, which
permits much faster heat-up after repairs – plus a simultaneous
increase of temperature resistance.
Let‘s talk about your goals. We‘ll find the right way.
Results first.
Intelligent RefractoryTechnology
REFRATECHNIK
Refratechnik Steel GmbH
Schiessstraße 58
40549 Düsseldorf
Germany
Phone +49 211 5858 0
aluminium@refra.com

ALUMINIUM INdUstry IN the GULf
the whole site. The road, which has been specifically
built to handle heavy goods vehicles,
will link the smelter with the processing plants.
Molten aluminium will be transported in crucibles
on special vehicles directly from the
smelter’s cast house to the end user. Besides
just-in-time delivery, this allows savings in
energy costs for remelting and / or reheating;
furthermore, users can specify the aluminium
alloy needed to meet their individual requirements.
The Emal smelter is the anchor tenant for Kizad’s aluminium cluster
New downstream additions
to aluminium cluster
Several aluminium processors have already
recognised the benefits of locating in the aluminium
cluster. Extruded profiles are a typical
downstream product and Taweelah Aluminium
Extrusion Company (Talex) will be
producing them in the aluminium cluster in
future. Talex is a joint venture between Senaat
and Gulf Extrusions. The latter has been operating
a modern extrusion plant with several
press lines in Dubai for several years.
At the end of 2011, Talex signed a longterm
agreement with Kizad for a 200,000
square metre site. The company will be investing
initially in two new press lines, which
are currently being engineered and built in Europe.
The company’s aim is to produce highquality
extrusion products to meet the specific
needs of the automotive market; end products
will also include transportation and industrial
materials, electrical and solar equipment,
road furniture and architectural materials.
Emal will deliver molten aluminium to
Talex via the Hot Metal Road. Special aluminium
grades will be alloyed and cast at Talex’s
own casthouse; standard grades can be obtained
directly from Emal as extrusion billets.
With the support of Emal and Kizad, Talex
will contribute further to the diversification
plan set out in Abu Dhabi’s Vision 2030. Majid
Al Ghurair, CEO of Al Ghurair Group and
managing director of Gulf Extrusions, is very
positive about the joint venture with AD-
BIC: “It is another step towards positioning
ourselves as a leading regional player in the
aluminium extrusion industry. The location of
Talex in Kizad is very important in terms of
being closer
to our raw
material supplier
(Emal) as
well as close
to the Khalifa
Port. With its
state-of-theart
equipment,
Taweelah Aluminium
Extrusion
Company
will be
a world-class
company competing
with the
best extruders
in global markets
by offering
premium quality
products.
This reaffirms our commitment to further
strengthen the region’s reputation as a leading
supplier in the extrusion market.”
Cast Aluminium Industries (CAI), a midstream
aluminium producer and recycler, is
another company planning to settle in the
aluminium cluster. On a 33,000 square metre
site, the company is erecting a plant for recycling
aluminium dross and other aluminiumbearing
waste materials produced by smelters.
CAI will be the first to represent ’horizontal
integration’ in the cluster. There is a zero
waste target with CAI also intending to play an
instrumental role in the waste-recovery management
of other investors in the cluster.
CAI has a wide array of clients in primary aluminium
smelters across the UAE (Dubal and
Emal) and the wider region including Alba,
Qatalum and other secondary smelters. CAI
is expected to commence operations in Kizad
in the third quarter of 2014.
CAI is Kizad’s first recycler and also the
first company that represents horizontal integration
in the cluster. Kizad has a zero-waste
target and CAI is intending to play an instrumental
role in waste-recovery management
for others in the cluster. Khaled Salmeen Al
Kuwari, CEO and managing director of Kizad,
© Emal
said: “Recycling is not a common initiative in
the local industrial business, therefore securing
Cast Aluminium as a partner who will play
a leading role in waste-recovery management
will change the nature of this business in the
UAE. By encouraging this, Kizad is working
towards two of our economic vision’s core
pillars: economic and environmental sustainability.”
CAI already operates three tilting rotary
furnaces with a combined capacity of 32,000
tonnes a year at its Dubai plant, with oxy-fuel
burners from the US and UK. A waste minimisation
programme initiated in 2004 successfully
reduced flux usage from 28 to 13 percent;
investment in a so-called ’alchemizer’,
which involves a mechanical segregation process
to enrich the aluminium dross, has resulted
in further reduction to nine percent. CAI
is also working with different companies to
utilise the alumina-rich dust from the alchemizer,
so far with promising feedback.
Opportunities still
available for investors
The new investors mentioned above are a
promising sign for the sustainability of Kizad’s
aluminium cluster. Negotiations are also taking
place with other potential investors. One
important missing link is a rolling mill for flat
aluminium products. Even though such plants
are currently being built in Saudi Arabia and
Oman, the UAE ought also to be an interesting
location for foreign investors. Besides the
possibility of erecting a conventional hot and
cold mill that processes sheet ingots supplied
by Emal, the Hot Metal Road also opens up
the opportunity to produce small quantities
economically using a strip-casting machine instead
of a hot-rolling stand. Foilstock for aluminium
foil could also be produced in such a
plant, possibly by an additional investor.
The Hot Metal Road might also be interesting
for the construction of an aluminium
foundry, for example for car wheels for both
the domestic market and export.
Given the diversity of possible finished aluminium
products, one could draw up a practically
endless list of possible investments. But
one thing is certain: there will soon be other
investors who appreciate the benefits offered
by locating in the Kizad aluminium cluster.
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.
40 ALUMINIUM · 9/2013

ALUMINIUM INdUstry IN the GULf
ePCM – a vital activity in the world of aluminium
The construction of aluminium production
facilities ranks alongside the biggest
of world projects, rivalled only by major
chemical process plants, city infrastructure
schemes, new underground transport
systems, harbour facilities and the like:
all huge enterprises elaborated on a massive
scale and involving a tremendous
complexity of operations – and of course,
associated multi-billion dollar costs.
The work required in building a major aluminium
smelter – greenfield or brownfield –
or an upgrade of downstream facilities, is invariably
on a massive scale, involving many
considerations, activities and complex components.
The necessary works involve extremely
close and careful coordination of all the individual
key parts of the project leading to completion
of the whole. Certain organisations
specialise in this vital work based essentially
on accumulated experience, knowledge – and
global reach.
EPCM – Engineering, Procurement and
Construction Management – is a common
form of contracting arrangement within
the aluminium / construction industry.
In an EPCM arrangement, the client, in
order to involve an experienced player
in large projects, selects a main contractor
who manages the whole project on its
behalf. The EPCM contractor essentially
ensures that the whole project is completed
as required to the client’s specifications
and on time. Normally, this involves
the EPCM contractor completing the basic
work such as site surveys, obtaining
clearances from authorities, undertaking
the basic engineering and also preparing
the site for the EPC contractors. Further,
the main contractor chooses the various
EPC contractors and ensures the elaboration
of the project as planned.
An EPCM contract is a natural progression
for an EPC contractor since, if
Construction work at the Emal Phase I smelter in spring 2009. SNC Lavalin was EPCM contractor for the Phase I
project and is also handling the EPCM services contract for the Phase II expansion.
the contractor has the capability to handle
the EPC work required in a project
then securing a wider role via an EPCM
job is advantageous. This helps to exploit its
current competencies while also ensuring better
control over the project. Also, the value
of the project managed through an EPCM
contract is far greater than the individual EPC
contracts.
A range of specialist EPCM companies is
called upon to offer total flexibility, and both
national and international experience in delivering
projects – from concept design through
to beneficial operation. This includes successfully
overseeing all elements of project and
construction management services, requiring
dedicated expertise at the cutting edge of a
diverse range of activities, including:
Feasibility studies and front end engineering
design: EPCM companies must ensure that
their imperatives of innovation, efficiency,
building capability and safety are embodied
into the fully integrated feasibility and detailed
design services offered, ensuring that all the
involved services are complementary. Costeffective
feasibility studies, embracing all sectors
and project locations, which take into account
the myriad of local and regional influencing
factors, ensure that projects are evaluated
accurately prior to the decision being
taken to progress to the next stage of design
and construction.
Project and risk management: Project management
and analysis of risk is a key element
of the services provided in all phases of EPCM
work. Experienced project management personnel
focus on developing an intimate understanding
of the client’s strategy, culture
and project needs from conception through to
completion.
Aluminium industry projects can range from
small-scale studies to multi-million dollar new
builds.
Construction management: EPCM organisations
must ensure that its construction management
services are naturally tailored to the
unique demands of both the client and project.
In all cases, construction health, safety and
environment are some of the key considerations
viewed to be of paramount importance.
Construction management teams are responsible
for ensuring that building work on
site is in accordance with the project specifications,
drawings and relevant standards indicated
by the integrated multi-discipline design
team. The main considerations here include
quality assurance, project site management
and project cost estimating, control and procurement
Once the EPCM gets the green light for
the proposed project, it is crucial that the
concluded work meets the stated objectives
and is delivered within the agreed cost and
time frame parameters. This requires robust
systems such as for value engineering and
analysis, cost estimating, reporting, management
and forecasting.
Multi-discipline engineering, detail design
and 3D modelling: Essentially, EPCM companies
work to add value to a client’s business,
through creative and innovative thinking in
engineering design. Integrated multi-discipline
engineering expertise across all related fields
is deployed to deliver an optimum solution,
based upon best practice and the very latest
project feedback available.
A range of recent EPCM projects in the
world aluminium sector reflect the huge scale
© Emal
42 ALUMINIUM · 9/2013

NEW
2013
NEW GENERATION OF VEHICLES
Reduced size and weight
Latest-generation electronics
Reinforced components for increased lifting
capacity
Long-comfort suspension cabin and swivel seat
Mobile alarm and data acquisition/
transmission system
Micro-controller management system and
on-board shock sensor
Smoother steering
Low maintenance costs
Check it out at the CIAC from October 21 to 25, 2013, in Montreal (booth B02)
and at the ARABAL conference from November 5 to 7, 2013, in Abu Dhabi (booth #16).
www.brochot.fr

ALUMINIUM INdUstry IN the GULf
© Qatalum
of the individual tasks involved for these main
contracting companies and also for their delegated
contractors down the line in meeting
the customers total plant requirements and
specifications.
Middle east projects
Fata EPC was EPCM contractor for the casthouse project at Qatalum
SNC Lavalin: Montreal, Canada-based SNC-
Lavalin is one of the leading engineering and
construction groups in the world and a major
player in the ownership of infrastructure, and
in the provision of operations and maintenance
services. The company is handling the
EPCM services contract for the Emirates Aluminium
(Emal) Phase II smelter expansion in
Al Taweelah, Abu Dhabi. The contract covers
the work to build a new aluminium facility,
including a 1,000 MW power plant and a 1.7
km-long potline, the longest ever built. Once
completed and fully operational in 2014, the
new facility will produce 525,000 tpy of aluminium
using an upgraded version of Dubal
DX technology, which allows for greater operating
efficiencies.
This latest contract followed SNC-Lavalin’s
successful completion of its EPCM mandate for
Phase I of the Emal smelter, which has a production
capacity of 800,000 tpy and included
the construction of a 2,000 MW power plant.
“SNC-Lavalin is a world leader in the design
and construction of aluminium smelters,
and we consider this new award as a clear acknowledgement
of the leading-edge technical
capabilities and experience we demonstrated
with Phase I of the project,” declared Riadh
Ben Aïssa, executive vice-president, SNC-
Lavalin Group. “Just as important, it reflects
the effort and importance SNC-Lavalin places
on maintaining long-term relations with our
clients. We value Emal’s relationship and trust,
and we are delighted with this new opportunity
to work together to build this landmark
project for the United Arab Emirates.”
Fata EPC: Fata EPC, a division of Italy/US
outfit Fata Hunter, was the EPCM contractor
for the casthouse build project at the Qatalum
primary aluminium smelter in Qatar, an equal
joint venture between Qatar Petroleum and
Hydro Aluminium of Norway. The casthouse
technology was supplied by Norsk Hydro delivering
an extrusion billet VDC capacity of
350,000 tpy and 275,000 tpy from 10 and 20
kg casters. Hycast hot metal alkaline removal
and in-line filters and degassers were installed
along with automatic casting sequencing. The
installation ensures that all equipment fumes
are treated by dust collectors.
In a parallel contract, Fata EPC also handled
work to build an anode baking plant at
the Qatalum facility with technology supplied
by Pechiney to provide a total plant capacity
of 368,000 anodes per year. The plant uses
seven fires with 116 sections and is fuelled by
natural gas with fume treatment employing
dry scrubbing. Storage provision was required
for 18,000 green anodes and 13,000 baked
anodes – and storage and retrieval is via automatic
crane and transfer.
Further, Fata EPC has also elaborated a series
of downstream projects in the aluminium
industry including others in the Gulf region,
such as the one currently in construction at
Oman Aluminium Rolling Company in Sohar.
As the main appointed EPCM contractor
to build the planned 160,000 tpy greenfield
facility, Fata EPC is managing the activities
involved to procure and install complete roll
plant systems to feature the latest available
technology in casting, rolling and finishing. The
new facility includes a Hazelett caster and a
hot rolling mill along with world-class cold
rolling and finishing equipment supplied by
Fata Hunter, the equipment division of Fata
SpA. For further project details, see report on
pages 34-37.
In Iran, Fata handled the second potline
expansion at the Almahdi Aluminium Smelter
in Bandar Abbas with key technology (provided
by Imidro). The plant’s Potline 2 comprises
two potrooms built 32 metres apart, each 750
metres long and 20 metres wide. A total of
228 pots, with 20 anodes per pot, employ
Dubal D20 cell technology, operating at 240
kA and 13.6 kWh/kg Al and using a fluid flow
alumina feeding system. Production capacity
is 147,000 tpy of aluminium.
Bechtel: Also in the Gulf, major EPCM
organisation Bechtel is extending its long
heritage of mega projects in the region by
managing the greenfield construction project
in Saudi Arabia for what is slated to be the
world’s largest aluminium smelter. The scope
of work involved in this USD4 billion project,
handled by Bechtel’s Mining & Metals division,
covers overall engineering, procurement,
and construction management.
The new smelter, a Ma’aden-Alcoa joint
venture, is the cornerstone of the Ras Al
Khair Minerals Industrial City, which will become
the country’s aluminium and phosphate
centre, north of Al Jubail in the Saudi Eastern
Province. This is part of a new integrated
USD10.8 billion aluminium complex, which
in addition to the smelter will include a mine,
alumina refinery and rolling mill. The smelter
facility will have a capacity of 740,000 tpy of
aluminium. Bauxite feedstock will be transported
via a purpose-built rail line from a new
mine at Al Ba’itha for refining and reduction
at Ras Al Khair. First commercial production
from the smelter and downstream rolling mill
is scheduled for 2013. For further project details,
see separate report on pages 46-47.
Again in the Gulf region, Bechtel’s Canada
operation has received a Letter of Intent (LoI)
from Aluminium Bahrain (Alba) to conduct a
Bankable Feasibility Study (BFS) for the smelter’s
planned Potline 6 expansion project, valued
at some USD2.5 billion. The study also
includes an economic analysis for the construction
of a fifth power station required for
the plant expansion. Alba’s Line 6 is expected
to produce an additional 400,000 tpy of aluminium
adding to its current 881,000 tpy, with
Dubal DX+ cell technology being used as the
basis of the study.
Bechtel has considerable specific industry
44 ALUMINIUM · 9/2013

sPeCIAL ArABAL
ALUMINIUM INdUstry IN the GULf
© Bechtel
Construction work at the Ma’aden-Alcoa joint venture early this year, with Bechtel the EPCM contractor.
From left to right: field engineers Fadi Elmourad, Muthukumaran Kuppusamy, Mohamad El Samad and
planner Lamont Berry.
Fluor Corporation’s Greenville, South Carolina
office is elaborating a design and procurement
contract awarded by the aforementioned
Ma’aden-Alcoa joint venture to build an integrated
automotive sheet manufacturing plant
that forms part of the aluminium complex.
The scope of Fluor’s work will include design,
construction and commissioning of the plant,
which will have the capability to produce a
range of products suitable for further downstream
manufacturing in the aluminium complex.
Once complete, the automotive sheet facility
will produce lightweight aluminium to be
used in vehicle manufacturing. These products
will include automotive heat-treated and nonheat-treated
sheet, building and construction
sheet, and foil stock. “This new manufacturing
facility will help meet the global automotive
industry’s growing demands for new, lighter
materials,” said Fluor head of Mining & Metals
business Rick Koumouris.
experience in the region having operated as
the EPCM contractor for the previous Line
4 and 5 expansions. The BFS is expected to
be completed by the third quarter this year,
and Alba projects that the new line could be
completed by early 2015. Alongside Bechtel,
BNP Paribas is acting as the financial adviser
for the project.
further ePCM projects
HRV Engineering / Hatch: In Iceland, Rio
Tinto Alcan is updating equipment, increas-
ANODE BAKING FACILITIES
The Riedhammer anode baking facility is a key component in a modern
anode production plant. Our plants offer many advantages such as:
• Customised design
• Excellent anode quality
• Extended furnace lifetime
• Low energy consumption
• High productivity
• Flexible equipment supply
• Safe operation
RIEDHAMMER
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
Klingenhofstraße 72
90411 Nürnberg
Phone: +49 911 5218 0
Fax: +49 911 5218 231
www.riedhammer.de

ALUMINIUM INdUstry IN the GULf
ing production capability and improving the
production process at its smelter casthouse
in Straumsvik. The project is aimed at boosting
productivity by 20%, to around 230,000
tpy, along with increasing the effectiveness
of air purification equipment and increasing
operational security by updating the electrical
equipment. Iceland outfit HRV Engineering,
in co-operation with Hatch, managed the
Isal production upgrade providing full EPCM
services in a project costing some USD500
million.
The plant’s operational reliability will be
increased with the upgrade and installation
of new HRV equipment and rectifiers. Plant
production is boosted by 40,000 tpy, involving
an amperage increase and an upgrade of the
two potlines, bath recycling plant and rodding
shop. New additional gas treatment centres
are included, along with alumina handling and
an upgraded general plant infrastructure.
The output is also being changed over from
rolling slab to extrusion billet, which requires
modification of casting equipment and installation
of three new continuous homogenising
furnaces.
Ausenco: Australian project contracting
company Ausenco is progressing the Innovate
and Create phase towards providing detailed
engineering design and construction management
services for the expansion and upgrade
of a carbon and paste plant at Rio Tinto Alan’s
aluminium smelter in Kitimat, British Columbia,
Canada. This new work is scheduled to be
completed by September 2013 and builds on
Ausenco’s previous early phase work on the
project during 2008.
Ausenco’s CEO Mimi Make sums up his
company’s role in another huge aluminium
industry project, and also the importance of
EPCM organisations across the sector in general:
“These contract awards demonstrate the
depth of our service offering and geographic
reach of our business. Our Process Infrastructure
business has achieved standout earnings
growth this past year and these latest wins further
demonstrate the benefits of our diversification
strategy and our global reputation for
project delivery to underpin further growth.”
Ken Stanford, contributing editor
Bechtel keeps building history
Engineering challenges do not come much
bigger than building the world’s largest
greenfield aluminium smelter project –
Ras Al Khair – located on the Arabian
Gulf, approximately 125 km north of
Jubail in the isolated north east corner of
Saudi Arabia. This location presented all
the usual challenges, including workforce,
equipment and permanent material logistics.
The USD4 billion project for the
Ma’aden-Alcoa joint venture is a key element
of the new Ras Al Khair Industrial
City – a showcase of Saudi Arabia’s industrial
diversification. It is all part of an
overall USD10.8 billion Ma’aden-Alcoa
investment that, in addition to the smelter,
includes an alumina refinery, rolling
mill, automotive mill and bauxite mine.
Recognised in the 2012 Bechtel Corporate Excellence
Awards as the Project Management
Team of the Year, the entire project team is
achieving some remarkable feats in this demanding
environment.
setting the standard for
safety attitude and performance
As of year-end 2012, the project team had
achieved 32 million job hours without a lost
time incident, with the customer team calling
Bechtel’s safety performance ‘world class’.
Many contractors have noted that the project
represents a turning point in their respective
firm’s safety attitude and performance.
“We’ve had exceptional success in building
a strong safety culture among more than
13,000 workers from around the world with
different levels of experience and exposure to
this type of work,” says Bob Sabo, Bechtel’s
Ras Al Khair site manager. “We must never get
complacent about safety, though. Every day,
we have new challenges, new contractors, new
disciplines and new workers coming onto our
site.”
“Our successes in safety have been gained
through a one-team, compliance-driven approach
with each stakeholder providing full
support to our zero accidents philosophy and
programmes,” says Terry Lyons, Bechtel’s environment,
safety and health manager at Ras
Al Khair. “I am always pleased to be able to
discuss an issue or proposed initiative and see
it put into action daily.”
Within budget, ahead of schedule
© Bechtel
Smelter alumina silos overlooking potrooms D to A north
“We have to-date safely achieved all of our
milestones ahead of schedule and within
budget,” says Denis Garrity, Bechtel project
director. “However, we cannot lose sight of
the final milestone – that all pots are ready to
start by end of 2013. It is the ability to safely
deliver a quality, well-engineered product, on
time and to budget, that has critical importance
to our customer.”
Unlike large, single potline aluminium
smelter projects previously completed by
Bechtel, such as Sohar in Oman and Fjardaal
in Iceland, the Ras Al Khair smelter includes
two high-amperage potlines and, at 740,000
tpy, will have nearly twice their total capacity.
Bechtel’s work also includes a cathode sealing
facility, a carbon plant for anode production
46 ALUMINIUM · 9/2013

sPeCIAL ArABAL
ALUMINIUM INdUstry IN the GULf
as well as port facilities for handling alumina, coke and liquid pitch,
and the world’s largest integrated casthouse.
founding success
Bechtel’s relationship with Ma’aden began when they were awarded
the feasibility study for the Az Zabirah Aluminium Project in 2003.
The company was then awarded the feasibility study for the Ras Al
Khair Project’s bauxite mine and alumina refinery. That study was
expanded to what will now be the world’s largest greenfield – and
Saudi Arabia’s first – aluminium smelter. Bechtel’s Civil business unit
is also performing master planning for the overall Ras Al Khair Minerals
Industrial City and serving as programme manager for the nearby
Jubail II Project – a USD10 billion major expansion of the city’s industrial
and residential areas, together with a major port addition.
W E C O N V E Y Q U A L I T Y
Defined Cooling of
Hot Bath Material
strong, predictable performance
Bechtel’s performance at Ras Al Khair, Sohar and Fjardaal is replicated
in a long line of successful greenfield and brownfield aluminium
smelter and alumina refinery developments.
The Yarwun 2 Alumina Refinery Upgrade Project in Gladstone,
Australia was completed in 2012 on schedule, under budget and
ramped-up on
plan. The project
expanded the original
refinery Bechtel
completed in
2004 (which, at the
time, was the first
greenfield alumina
refinery constructed
anywhere in the
world in 20 years).
Bechtel shares a
long, successful
history with Gladstone’s
alumina industry,
having also
built the Boyne Island
smelter in the
early 1980s. This
facility was also expanded
by Bechtel
in 1996.
The company
Gas treatment centre No. 1 and potrooms A and B in is also currently
operation with the green anode plant in the background
completing the
feasibility study
for the Line 6 Expansion Project in Bahrain for Alba, and modernising
the 60-year-old Kitimat aluminium smelter in Canada for Rio
Tinto Alcan (RTA). Modernising Kitimat will create an environmentally
superior, safer and more productive plant, elevating RTA’s
British Columbia Operations entity to a world-class aluminium producer.
With Ras Al Khair due for completion in late 2013 and Kitimat due
to produce its first aluminium in late 2014, Bechtel has an exciting
few years ahead. Tasked with delivering two demanding projects in
two polar opposite environments, Bechtel is once again meeting the
challenge.
■
ALUMINIUM · 9/2013
For the Primary Aluminium
Smelting Process
AUMUND Foerdertechnik GmbH

ALUMINIUM INdUstry IN the GULf
Company profile: Aluminium Bahrain B.S.C.
One of the largest aluminium smelters in the world
Aluminium Bahrain B.S.C. (Alba) consistently
ranks as one of the largest and most
modern aluminium smelters in the world.
Known for its technological strength and
innovative policies, Alba enforces strict
environmental guidelines, maintains high
track record for safety and is widely regarded
as one of the top ten performers
on a global scale.
It supports numerous community oriented
programmes and social activities that have
underlined its status as one of Bahrain’s leading
industrial organisations that remains committed
towards upholding its corporate social
responsibilities. Alba’s inception marks the
beginning of Bahrain’s strategy to diversify
its economic base and reduce its dependence
on oil. The aim was to establish an industry
that would provide valuable
export earnings, develop the
country’s resources and create
training and employment opportunities
for a large number
of Bahrainis. Alba was therefore
incorporated by Charter
in 1968 and officially commenced
operations in 1971 as
a 120,000 tpy smelter.
Alba today produces more
than 890,000 tpy of the highest
grade aluminium, with products
including standard and T-
ingots, extrusion billets, rolling
slab, properzi ingots and molten
aluminium. Around 50% of
output is supplied to Bahrain’s
downstream aluminium industry,
with the rest exported to
regional and international customers
in the Middle and Far
East, South East Asia, Africa,
Europe and North America.
The Alba plant comprises
five reduction lines, three
casthouses, a dedicated carbon
plant, a 550,000 tpy coke calcining
plant, a water desalination
plant, eleven fume treatment
plants, a marine terminal, and a 2,225
MW power plant, consisting of four power
stations. The plant also features a ten hectare
‘green’ oasis, with more than 7,600 trees and
shrubs, a fruit and vegetable garden, and an
artificial lake.
Aerial view of the Alba site
Alba’s early success established a blueprint for
other non-oil industries to follow, including a
thriving downstream aluminium industry. Today,
the company is a major contributor to
the social, industrial and economic development
of the Kingdom of Bahrain, employing
over 3,000 people, of whom around 90% are
Bahrainis.
The entire plant operates to the Environmental
Management System standard ISO
9001:2000 and the casthouses and marketing
are also operating to the ISO 9002 Quality
Management System. Recently, the casthouse
was upgraded to the 2008 version of
ISO 9001, enabling Alba to be the first metals
manufacturing company in Bahrain to receive
this major upgrade.
The company has won a number of awards
including the inaugural Shaikh Khalifa bin Salman
Al Khalifa Award for Industrial Excellence,
the International Millennium Business
Award for Environmental Achievement from
the United Nations, safety awards from the
British Safety Council and The Royal Society
for the Prevention of Accidents, and a GCCwide
award for human resources development
and nationalisation of the workforce.
The shareholders of Alba are Bahrain
Mumtalakat Holding Company (69.38%),
Sabic Investment Company (20.62%) and the
General Public (10%).
Main highlights
Line 6 expansion project: Alba is progressing
to become one of the largest single site
aluminium smelters in the world through the
Line 6 expansion project, which is expected to
add 400,000 tonnes to Alba’s current production
capacity of 890,000 tonnes, bringing the
total annual production to around 1.3 million
tonnes.
A major phase in Alba’s growth history,
the Line 6 expansion project has gained significant
momentum with the
launch of the Bankable Feasibility
Study (BFS) in December
2012. Bechtel Canada
has been awarded a Letter of
Intent (LoI) to perform the
BFS for the Line 6 expansion
project, and Dubal DX+ technology
will be used as the basis
for this study. The BFS is expected
to be completed by the
first quarter of 2014.
Continued focus on safety:
Safety is regarded as an intrinsic
part of the work life in Alba
and the company is committed
to continuously providing
a safe and healthy work environment
for everyone.
To strengthen the company’s
focus on safety, the Alba
SafeWay Programme was
launched in the second half
of 2012 with three main objectives:
ownership of safety
is everyone’s responsibility;
working safely is a condition
of employment; and all workrelated
injuries and illnesses
are preventable. In addition,
activities and programmes to increase safety
awareness in all aspects of the employees’ life,
both at work and at home, were conducted
and implemented on a plant-wide basis. Some
of these are highlighted below:
• The first HSE Week was launched from 25
© Alba
48 ALUMINIUM · 9/2013

sPeCIAL ArABAL
ALUMINIUM INdUstry IN the GULf
Aluminium billets, ready for shipment
February to 4 March 2013 and aimed at creating
a culture of zero accident work environment
• The second HSE Week from 30 June to 4
July 2013 highlighted summer safety awareness
by focusing on heat stress, heat exhaus-
tion, heat related illness, proper food
habits, road safety, contractor safety
awareness, etc.
• The eBehavioural Observation
programme, a key leadership activity,
was further enhanced and implemented
across departments to increase safe behaviour
amongst employees.
Other significant achievements: Alba
increased its sales for the first six months
of 2013 by 1.9% year-on-year thanks
to a focused marketing strategy while
production for the same period rose by
2% y-o-y on the back of strong operational
improvements.
The company’s physical premiums
remained strong and value-added products
accounted for 66% of total shipments
in the first half of 2013.
Potline 5 was up-graded using inhouse
expertise and technical skills to
operate at 370 kA.
Successful completion of USD169
million local bond facility refinancing in the
first quarter of 2013.
■
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.
Subscription service
vertrieb@giesel.de | Fax +49 (0)511 7304-233
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

ALUMINIUM INdUstry IN the GULf
successful start-up of the fume treatment
centre at ras Al Khair aluminium smelter
J. de Weerdt, P. Klut; danieli Corus
Two FTC’s were built in Ras Al Khair,
Kingdom of Saudi Arabia, as part of the
Ma’aden aluminium complex. These
FTC’s treat the fumes of two anode
bake furnaces that supply anodes to the
740,000 tpy aluminium smelter. FTC 2
was commissioned in October 2012 and
is currently running at full capacity. The
cold commissioning of FTC 1 was done
in January 2013, and hot commissioning
took place in June 2013. As with all startups,
there were some challenges to overcome,
but currently FTC 2 is fully operational
and FTC 1 is running at about 50%
of its capacity because not all fires at the
anode bake furnace 1 are in operation
yet. Both FTCs are performing satisfactory.
FTC 2 performance tests have taken
place in the first week of July 2013.
The Ras Al Khair aluminium smelter project
is a USD10.8 billion joint venture between
Saudi Arabian Mining Company (Ma’aden)
and Alcoa. The aim of the smelter project is
to realise world’s largest and most efficient
aluminium complex with a yearly capacity of
740,000 tonnes. The project’s alumina refinery,
aluminium smelter and rolling mill are located
at Ras Al Khair, 90 km north of Jubail.
The aluminium smelter consists of two potlines
of 360 pots each, using AP37 technology.
There are two anode bake furnaces, ABF 1
having four fires and ABF 2 having three fires,
that produce anodes for the potlines. Both
ABF’s have their own dedicated FTC to treat
the fumes from the fires. FTC 1 consists of
six baghouses and four main exhaust fans (of
which 3 duty and 1 standby) treating the fumes
of ABF 1. FTC 2 consists of five baghouses and
three main exhaust fans (of which 2 duty and
1 standby) treating the fumes of ABF 2. Table
1 summarises the process design data for FTC
1 and FTC 2.
The objective of the FTC’s is to meet the
client requirements in terms of ease of operation,
high online reliability, maintenance
friendliness while performing to comply with
the stringent local environmental legislations
on airborne emissions. The fume composition
and maximum emission levels are listed in
Table 2.
Type of pollutant
the ftC design
Fume composition
[mg/Nm 3 ]
Maximum
emission
[mg/Nm 3 ]
Gaseous fluorides 0 – 200 < 0.5
Particulate fluorides 0 – 50 < 0.6
Total particulates 0 – 200 < 5.7
Condensed soluble tars 0 – 200 < 1.7
Table 2: Fume composition and maximum emission
levels
The most notable achievement in this project
was the short time required for the engineering
and fabrication of both FTC’s. The total time
for the engineering of two complete FTC’s was
only nine months, while only five month after
placement of the purchase orders the first
FTC 2 equipment arrived on site.
Danieli Corus purchased equipment worldwide
and transported it to site in order to meet
the tight schedule. Despite the sometimes
challenging custom clearance, availability of
material within KSA, working pressure and
deadlines that had to be met, all equipment
arrived at site within a relatively short period
of time.
Furthermore, the equipment was supplied
in large module delivery which had a major
impact on site labour requirements since less
site welding was required compared to combining
a series of smaller components. Also,
the complete piping system was prefabricated
in order to reduce site labour required.
This type of modularisation in combination
with the split of responsibilities between
manufacturing and the erection could only
be accomplished with a detailed 3D model
to avoid interferences on site. A detailed 3D
model for both FTC’s was made in which the
Fig. 1: Modular design, left – preassembled baghouse, right – fully fabricated cooling tower
© Danieli Corus
Process Variable FTC 1 FTC 2
Fume volume (Am 3 /h) 245,000 180,000
Fume temperature (°C) 220 220
Underpressure at ABF (kPa) -2,000 -2,000
Number of baghouses 6 5
Number of main exhaust fans 3 + 1 2 + 1
Alumina utilisation (t/hr) 6 4
Table 1: FTC 1 and FTC 2 process design data
Fig. 2: Modular design, left – preassembled stack section in laydown area, right – installation of preassembled
stack section
50 ALUMINIUM · 9/2013

ALUMINIUM INdUstry IN the GULf
Fig. 3: 3D model for FTC 1 (front) and FTC 2 (back)
3D models of the steel structure, equipment
and piping layout were combined into one
single model for the entire FTC.
Some additional items requested by the client
were implemented in the Danieli Corus
design, including a burner to reheat the gases
from the ABF in order to prevent acid condensation.
No substantial design modifications with
respect to the proven and tested Danieli Corus
design FTC’s were made, but numerous small
modifications were introduced in the design
and fabrication process in order to reduce the
required time from the start of the project until
mechanical completion and to supply the
FTCs meeting client’s requirements and specifications.
In addition, design and constructability
improvements that were identified in
previous FTC’s designed by Danieli Corus
were incorporated in these two FTC’s. This
includes the FTC compac design, in which the
stack and cooling tower are installed adjacent,
leading to structural advantages and more
convenient access for daily operation and
maintenance.
Due to these features, the time between
the start of the installation preparations and
the mechanical completion of the two FTCs
was only one year.
Operating environment
The construction of FTC 2 was nearly completed
at the end of August 2012, and cold
commissioning started at this time. One of the
major challenges during the commissioning
of FTC 2 was that construction work on FTC
1 was still ongoing, while FTC 2 was already
completed and being commissioned. This required
strict safety measures and careful coordination
of construction and commissioning
work to create a safe and secure working environment
for all employees.
This was achieved by
implementing an extensive
Lock-out Tag-out (LoTo)
system. This LoTo system
made it possible to conduct
both construction and
commissioning at the same
time in a safe manner. In
addition, the LoTo system
did not delay construction
work, while still ensuring
a safe working environment.
Construction was done
in cooperation with
DC’s affiliate company
Inbesco, with a solid base and extensive experience
in the middle East. Due to this successful
partnership, it was possible to complete the
construction work for both FTC 1 and FTC 2
in an effective way from quality as well as
safety and timing point of view.
Also client engineer Bechtel was closely
involved in the design, construction and commissioning
phases. The cooperation with Bechtel
was very fruitful and sped up the whole
process as Bechtel took care of issues that
could have led to delays. Also, weekly commissioning
meeting were initiated by Bechtel
in which potential construction and commissioning
issues were discussed and resolved.
Preparations
Commissioning checklists: During the engineering
phase of this project, a commissioning
manual was made and approved by Bechtel
and Ma’aden. This manual was used as a
guideline for this job. This included basic mechanical
equipment checklists for construction
completion and pre-commissioning.
Process parameter
tables such as pressure and
amperage values were noted
on the checklists as means
of reference.
During any future recommissioning
activities, the
original parameters would
be useful in re-establishing
the successful operation.
On site, these basic
guidelines were refined in
close cooperation of Bechtel
and Ma’aden to develop the
best hand over package to
the owner. The documentation
was used to evaluate
the performance and for future reference.
Safety: As with every construction project,
safety was given paramount priority. For
every stage of the commissioning, a thorough
checklist was made incorporating a complete
and detailed safety analysis. All aspects of the
safety plan were discussed with all contractors
and trade disciplines and mutually agreed
to comply with the project safety standards.
Also, Danieli Corus maintained its own LoTo
system to ensure a safe working environment
for all employees.
Cold commissioning
Fig. 4: FTC 1 (front) and FTC 2 (back)
Start-up / cold commissioning is the process
of placing a system or portion of a system in
operation for the first time under ‘live conditions’
to ensure correct plant functionality.
The cold commissioning started when pre-operational
testing activities had been completed
by the commissioning team. It was scheduled
to minimise interference with bake furnace
start-up.
FTC 2: Cold commissioning of FTC 2 went
satisfactory and was completed in time for
the dry-out of ABF 2. During the dry-out, the
FTC was operating in bypass mode and fumes
with high moisture content but no pollutants
were extracted from the ABF.
FTC 1: Cold commissioning of FTC 1 took
place in January and February 2013 and
took about four weeks in total, including all
pre-commissioning activities and turnover to
client. Because both FTC’s are identical and
some issues that had been found during the
commissioning of FTC 2 had been addressed
for FTC 1 already, the cold commissioning
went very smooth and no major issues were
found.
Due to efficient cooperation with Inbesco,
it was possible to resolve all punch list items
52 ALUMINIUM · 9/2013

sPeCIAL ArABAL
ALUMINIUM INdUstry It‘s IN a pure the waste GULf of time
... if you make do with anything less!
for FTC 1 as well as FTC 2 and leave site with
the both FTC’s handed over to the client, FTC
2 in full operation and FTC 1 ready for hot
fumes.
first ‘hot fumes in’
FTC 2: Dry-out of ABF 2 started in the beginning
of October 2012 and continued for about
four weeks. During this time, FTC 2 was operated
in bypass mode and only provided draft
to the ABF, but no fumes were treated. On 5
December, the first hot pollutant containing
fumes were treated by FTC 2. At this time, the
FTC was operated with only two baghouses
and one MEF because of the low amount of
fumes.
to sub-systems for which, after careful inspection,
a list of punch list items was prepared.
Once a sub-system had been completed,
the client was invited for a walk-down to
identify any additional punch list items and
to verify the punch items that had been resolved.
When all ‘A’ punch items had been resolved,
the sub-system gained the purple-tag
status (mechanical completion), after which
the commissioning could start. During commissioning,
the remaining ‘B’ and ‘C’ punch
list items were resolved and after a second
walk-down with the client, the sub-system
was grey-tagged (practical completion) and
officially handed over to the client.
Along with the handover of the FTC itself,
also an extensive handover document package
was prepared including construction
and engineering documents,
specifications, as well as
test procedures, commissioning
documents, and manuals. Once
these documents and the punch
lists had been signed-off by the client,
the FTC was officially handed
over and operated by Ma’aden
employees from that moment on.
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).
Fig. 5: DC lock-out Tag-out system with equipment locks (red)
and personal locks (green)
Excess air had to be withdrawn through the
ABF dilution air damper to ensure sufficient
airflow at the MEF. This situation continued
for about four weeks and the operation became
more stable when also the second and
third fires of the ABF were taken into operation.
Currently, FTC 2 is operation at full capacity
and performing excellent. The fresh alumina
rate of about 1.5 tph and carbon contents
are well below maximum acceptable level.
FTC 1: Because ABF 1 was not ready to
start producing anodes when the cold commissioning
of FTC 1 was finished, hot commissioning
of FTC 1 took place in June 2013.
Like the cold commissioning, the hot commissioning
of FTC 1 went smooth and could be
completed within one week.
Guarantee measurements
At the time this article is being issued,
the guarantee measurements
for FTC 2 just have taken place.
Guarantee measurements of FTC
1 will take place when ABF 1 is
running stable with all four fires in operation.
Currently, only two fires are in operation of
which one is for dry-out.
Conclusions
The start-up of both FTC’s on Ma’aden ABF
1 and ABF 2 was successfully completed to
the satisfaction of all parties. The FTC incorporated
new design features from Danieli
Corus that enhance the safety and operability,
maintainability and emissions performance. It
was a clean start-up with the new furnace,
thanks to the close coordination of DC, Inbesco
and Bechtel during hot and cold commissioning.
There were minimal by-pass events
which meant emissions were maintained even
during the commissioning phases.
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
handover
Handover to the client was organised through
an extensive procedure which involved mechanical
as well as practical completion. Within
this procedure, both FTC’s were divided in-
Authors
Peter Klut is senior process engineer at Danieli
Corus B.V., Velsen-Noord, The Netherlands
Jan de Weerdt is process engineer at Danieli Corus
B.V., Velsen-Noord, The Netherlands
Account no
Q The price will be remitted on receipt
of the invoice
Date
Signature
ALUMINIUM · 9/2013
Subscription service
vertrieb@giesel.de
Fax +49 (0)511 7304-233

ALUMINIUM INdUstry IN the GULf
© Fives Solios
high performance of ‘eolios’ pitch fume
treatment system at Qatalum paste plant
RTO plant at Qatalum
Since the introduction of paste-coolers
in the anode manufacturing process, the
amount of volatile compounds has drastically
increased; in parallel, standards of
emission levels became more stringent.
Consequently, the technologies to treat
such emissions must cope with more concentrated
streams at inlet and lower emission
requirements at outlet. Solios has
developed the ‘Eolios’ system which is an
optimised combination of a dry scrubber
based on the adsorption of PAH on coke
fines, and a RTO (Regenerative Thermal
Oxidiser) using oxidation technology.
This combination minimises the energy
consumption while maximising the treatment
efficiency.
never reached before for such installation.
With 1 mg/Nm 3 of PAH 16
(according to the NS 9815 Norwegian
Standard), it can be considered
a new benchmark in the Gulf.
Coal tar pitch – the source
of PAhs emissions
PAHs are the main components of
coal tar pitch, which is used as a binder
for the fabrication of anodes. Coal
tar pitch is a solid material at ambient
temperature; to be used in the manufacture
of anodes it must be heated to
become liquid and to be mixed with
aggregate (calcined petroleum coke)
to obtain a homogeneous paste: this
step is done at approx. 160-200 °C.
At such range of temperature, the
coal tar pitch releases a high amount
of Coal Tar Pitch Volatiles (CTPV),
which are mainly composed of Polycyclic
Aromatic Hydrocarbons (PAH). Some
of these molecules are known or suspected
to be highly carcinogenic. The PAHs can be
divided into two groups: the light and heavy
fractions. This classification depends on the
number of aromatic rings present in the PAH
molecule. When the PAH is composed of, at
least, three aromatic rings, we can say that it
is a heavy PAH. Depending upon their molecular
weights, PAHs exist either under solid
form (particulate PAHs) or gaseous form (gaseous
PAHs), or both.
Paste mixer
Coke + Pitch
The addition of water to cool down the anode
paste lowers the partial pressure of the vapour
generated by the paste, which displaces the
equilibrium towards production of the light
fraction; so all the PAHs with a low partial
pressure (the light fractions) are released in
gaseous form.
Consequently, the addition of water into
the paste-cooler has drastically increased the
amount of light PAHs. This phenomenon was
confirmed in the Deschambault paste plant
before and after the installation of a pastecooler:
the PAH emissions increased by a factor
of 6.
Pitch fumes are generated in all equipment
where coal tar pitch is used at high temperature
(160-200 °C). It was observed that the
pitch volatiles concentration is doubled when
the temperature of the liquid pitch increases
by 20 °C. So the mixing temperature is also a
parameter with impact on the PAH emissions.
Conventional coke dry scrubbing system
The dry scrubber system is derived from the
potline alumina dry injection scrubbing technology.
It consists in injection of coke fines in
a gas stream loaded by pitch fumes. An adsorption
phenomena occurs between the coke
and the pitch fumes: the large specific area
(6,000 to 7,000 Blaine) and opposite electrical
charge of the coke fines allow adsorption
of pollutants.
The fines fraction of coke readily available
for the preparation of the anode paste is
injected counter-currently to the fume-laden
stream. Turbulence and highly efficient contact
between the pitch fumes and aerosols are
The first Eolios system was installed at the Alcoa
Moesjen anode plant in Norway in 2007
to treat the higher concentration streams coming
from the paste-cooler. Solios observed destruction
efficiency from 97 to 99% on PAH.
In 2010 a second Eolios system was implemented
at Qatalum. In January this year, Solios
successfully completed the performance
tests for the pitch fume treatment system at
the Qatalum green anode plant. With a production
capacity of 60 tph, it is the world’s
largest single line green anode plant.
The PAH sampling and analysis, done by a
third party, demonstrate a level of emissions
+ Water
Paste cooler
Anode former area
Coke fines injection
Fig. 1: Dry scrubbing process
54 ALUMINIUM · 9/2013

sPeCIAL ArABAL
ALUMINIUM INdUstry IN the GULf
promoted in the Venturi
reactor. Pitch loaded fines
are then collected by a dust
collector (bag filter) and are
reintroduced into the anode
paste recipe. The clean
gases are then released to
the atmosphere (Fig. 1).
The pitch loaded fines
are then recycled and used
into the recipe for the anode
manufacturing process:
there is neither waste
stream nor product loss.
The global capture
efficiency of dry scrubbing for PAH
is about 95%; this efficiency is higher
for heavy PAH (up to 99%).
The dry scrubbing system philosophy is
based on the ability of PAH to condensate:
this allows to be adsorbed on the fines coke
surface. So, the efficiency is better with heavy
PAH that condensate easily. For the lighter
PAH, mainly emitted from the cooler as
noted above, the efficiency of this technology
is limited: if there is no condensation, no
adsorption will occur and the pollutants pass
through the bag filter without being captured.
The condensation depends, obviously, of the
ambient temperature: in cold countries the
capture efficiency of the dry scrubber is better
(up to 98%).
For this reason new technologies based on
oxidation reaction are used in order to improve
light PAHs treatment efficiency.
rtO – an effective method
of destroying PAhs
The Regenerative Thermal Oxidation (RTO)
is based on the oxidation principle. PAHs are
mainly composed by C-H bonds which are
easily cracked by oxidation according to the
RedOx reaction (combustion reaction):
C a H 2b + (a+b/2) O 2 → aCO 2 + bH 2 O + Heat
All PAHs are converted into carbon dioxide
and water vapour.
The RTO is a compact equipment composed
of three main elements:
• The combustion chamber where the oxidation
reaction occurs. The temperature in the
combustion chamber is about 850-900 °C.
• The ceramics beds, which are used as heat
exchangers. The aim is to store heat and to
recover if for preheating the inlet gas flow, and
thus save energy.
• The valve box: two valves for inlet and
outlet ducts, and one valve for purge for each
chamber.
The raw gas (1) is introduced via the valve
Fig. 2: RTO – schematic diagram
box into the tower B, and pre-heated passing
through the ceramics (5) to achieve the
required temperature for the combustion of
PAH (at least 850 °C). The residence time in
the combustion chamber (6) is about 1-2 sec,
this time will do to destroy PAH. The combustion
of PAH generates heat which reduces
the consumption of the burner (7). The clean
gas is conveyed from the combustion chamber
into the second heat exchanger A, and is then
released through the exit stack (9). The third
heat exchanger C is in purge mode in order to
remove the remaining raw gas residues (Fig. 2).
eolios at Qatalum paste plant –
an innovative solution for
optimum emission performances
At the Qatalum paste plant, the highly concentrated
fumes, which are collected from the
paste cooler and which contain mainly water
vapour and light PAH fractions, are specifically
treated by the RTO unit. To avoid condensation
of tar in the duct, it is necessary to
heat up the fumes with hot air in a mixing
pot, situated on the paste cooler. After mixing,
diluted fumes enter into the RTO unit at a temperature
of 150 °C. After the RTO treatment,
the clean gas is rejected to the atmosphere.
All others suction points (mixer, vibrocompactor
area, etc.) are treated by the dry scrubbing
system (Fig. 3).
Paste mixer
Paste cooler
Calcined
petroleum coke +
liquid pitch
+ Water
A set of FID (Flame Ionisation Detector)
measurements were performed in order to
estimate the relationship between RTO temperature
and destruction efficiency. The gas
sample is continuously sampled into the FID
which measures the concentration of total
volatiles organic compounds.
The FID measurements done at the Qatalum
plant show that higher temperature combustion
creates an improved RTO efficiency
due to the increase of organic compounds
destruction:
RTO combustion
temperature
RTO efficiency
840 °C 91.2%
870 °C 96.2%
The PAH sampling and analysis, done in the
common stack, confirm the high efficiency of
the optimised combination of a dry scrubbing
system and RTO with a level of emissions
never reached before for such installation,
and which is now considered as a new benchmark
in the Gulf at 1 mg/Nm 3 of PAH 16 according
to the NS 9815 Norwegian Standard.
Environmental emissions are becoming
more and more stringent, especially for carcinogen
substances such as PAHs from pitch
vapour. Eolios, which combines dry scrubbing
and RTO, allows to operate the green anode
plant while maintaining the PAH’s emissions
at stack below such stringent requirements.
Eolios leads to lower operating costs and
a smaller carbon footprint than alternative
technologies such as full RTO, for instance.
The first industrial implementations of
Eolios at the Moesjen paste plant and recently
at the Qatalum paste plant confirm the performance
and benefits associated with this
technology.
■
RTO
Stack
Coke Fines Injection
Dry scubbing system
Others suctions point
(anode forming area
mixer....)
Fig. 3: Eolios system at the Qatalum paste plant
ALUMINIUM · 9/2013 55

teChNOLOGy
Shipped all over the world from the Eifel region
Köllemann Gmbh – market leader for petcoke preheaters
Köllemann GmbH from Germany is engaged
in every industrial sector where
there is a need for bulk solids to be
conveyed, heated and cooled
in a continuous process. For
the aluminium industry, the
company designs and builds
petcoke preheaters, which are
used in the production of anodes. Köllemann
preheaters are among the largest
on the market. They are designed to
ensure optimal mixing of the petcoke,
with minimal deviations in temperature
and a long service life that requires little
maintenance.
Köllemann GmbH was founded in the 1960s
and is based in Adenau, Germany, near the famous
Nürburgring motor-racing circuit. Originally
owner-managed, the company is now in
the hands of financial investors. It has been
under new technical and commercial management
since the middle of last year, although
core personnel engaged in design and manufacturing
are still with the company. “The
change of management has given the company
a new impetus,” explains Guido Fiedler, head
of Development and Design. “We are working
intensively to further improve our working
procedures and to adopt a more proactive
approach to marketing our products.”
The company is active in all sectors where
there is a need for a combination of conveying,
heating and cooling of bulk solids in a continuous
process. Important keywords here are
the dosing, sealing, metering, mixing, heating,
conveying and feeding of bulk solids.
Köllemann’s standard portfolio covers rotary
valves, screw heat exchangers, petcoke
preheaters and contact dryers. The company
Hollow flights
Tube with annular gap
Double-walled trough
Product level
is ASME and ISO 9001 certified; pressure vessels
are manufactured in accordance with AD
2000 regulations.
The company supplies its machines worldwide
to a number of raw materials processing
sectors, such as the chemical, petrochemical,
cement and metal industries and the power
sector, as well as for wastewater treatment
plants, to name but a few.
“We want to intensify
contact with end-users”
For the aluminium industry, Köllemann designs
and manufactures the petcoke preheaters,
used in anode-making. The preheater
heats up the petcoke and mixes it thoroughly
to a homogenous mass. This mixture is subsequently
blended in a kneader with hot pitch
and anode butts to produce green anodes. This
is a continuous conveying process.
The preheaters use screw flights as the main
heat-transfer surface; these are based on the
hollow-flight principle. Thermal oil acts as the
heat transfer medium and flows through the
hollow flights. “With our largest units we can
heat up to 60 tonnes of petcoke an hour to a
temperature of 220 °C,” says project manager
Matthias Ginster. Four worm shafts are used.
The heat-exchanging surface is 300
square metres or more and the units
weigh some 80 tonnes.
Köllemann regards itself as the undisputed
market leader for petcoke preheaters:
“We supply some three-quarters
of the global preheater market,”
says Mr Ginster. “Nevertheless, we
rarely deal directly with plant operators.
This is because we don’t usually supply
to the end-user, but to the supplier of the
plant that makes the kneaders for the anode
paste. From a process engineering point
of view, kneader and preheater operate as a
single unit.”
Köllemann is a hidden champion, so to
Köllemann preheaters
are of modular design, with
easy access for maintenance
speak. However, in future the company wants
to get more involved in the market and deal
directly with end-users. “We want to boost our
business still further and grow. To achieve this,
we want to intensify contact with end-users
and become more involved in the marketing
of our preheaters. We think that it will also
be beneficial for the operators of our plant
to have closer contact with our company, for
example in order to obtain direct support without
having to take a roundabout route via the
supplier of the kneaders,” says Mr Fiedler.
When asked what differentiates Köllemann
machines from those of its competitors, Mr
Ginster replies: “Our machines are particularly
durable, require little maintenance and
are easily accessible. The whole unit is a modular
construction.” All preheaters supplied by
Köllemann are constructed in accordance with
the customer’s specification, starting with the
machine size, connections and other productrelated
aspects. “On request we can supply
turnkey machines with the pipework already
completely installed. Our designs are based in
principle on the German industry standard.
This means we only ever use planetary gears
for petcoke preheaters that have a service life
that is at least equal to that of the machine itself.
If customers want drive systems or measuring
equipment from specific manufacturers,
they can have these as well.”
Köllemann guarantees the supply of spare
parts for many decades. The company still has
details of machines it supplied in the 1960s,
from the days when nobody had even dreamt
of PCs and CAD.
special design features of coke preheaters
There are three identical Köllemann preheaters
in the anode plant at Emirates Aluminium
(Emal): two preheaters have an hourly capacity
of 40 tonnes and a third unit operates as a
cooler, cooling the anode butts after they have
been crushed into small pieces.
© Köllemann
56 ALUMINIUM · 9/2013

teChNOLOGy
The standard practice with such large preheaters
is to have two right-hand shafts and two
left-hand shafts, with only one shaft being
motor-driven and the other three shafts being
driven by toothed gears. “For Emal, the shaft
driven by toothed gears is identical in construction
to the motor-driven shaft. Although this
requires more design effort, as well as more
material, it reduces the spares that have to be
kept in stock should a fault occur. Therefore
only one right-hand shaft and one left-hand
shaft are needed for all three units.”
Mr Ginster points out that the largest machines
available have always been supplied by
Köllemann. For example, there is a preheater
with a capacity of 50 tonnes an hour at Alcoa
Mosjøen in Norway. Köllemann
also recently supplied a 60t/hunit
to an anode plant in China
– the largest preheater currently
available on the market.
Köllemann preheaters have
a number of distinguishing features.
Small mixing paddles are
attached to the outside of the
shaft to better loosen and mix
the product, and ensure that the
kneader can thoroughly wet the
petcoke with pitch without difficulty;
this results in optimal, homogenous
mixing of the petcoke
and avoids hot spots.
The preheaters are designed
so that they are very easy to
service: all parts of the unit are
readily accessible to maintain
the shaft exits and the sealing
elements. Furthermore, the seals
where the shafts exit the machine
housing can be removed
completely from the top without
having to dismantle the whole
console. The worm itself does
not require any maintenance
and is characterised by a long
service life, measured in terms
of decades.
The bearings, too, have been
specially designed. “I have seen
competitive products which
have the riskiest designs of bearing
possible,” says Mr Ginster.
“However, at the ends we use
maintenance-free high-temperature
bearings made from special
graphite; these allow the shaft
to be swivelled slightly and to
move freely along its length. This
means thermal expansion does
not exert any stress on the shaft,
WWW.BUSSCORP.COM
which thus increases its service life. We also
use a double bearing so that the toothed gears
mesh accurately, which is also very maintenance-friendly.”
The preheaters are also characterised by
very good insulation and thanks to which
there are hardly any heat losses. The thick
insulation does not only ensure high energy
efficiency though: above all it is important for
occupational safety. “Our preheaters are only
lukewarm on the outside even though there
is thermal oil at 300 °C flowing through the
shafts. We thus conform to the latest machinery
directive even though the preheaters are
used in countries where such requirements do
not apply.”
The leading Mixing Technology
for Anode Pastes
The insulation (rock wool) is also of modular
design and can be removed and installed again
without damage. It is cassette-type insulation
with clips holding the cassettes together.
fit for the future
Köllemann is already undertaking development
work for a new generation of preheaters
in order to be well prepared when hightemperature
pitch is increasingly used in a few
years’ time; such pitch does not melt until it
reaches 300 °C, in contrast to the 180 °C that
is the case with the standard pitch commonly
used today. The reason for this change is
that a new environmental directive that forbids
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 · 9/2013

teChNOLOGIe
Köllemann recently supplied a 60t/h coke preheater to an anode plant in China – the largest machine currently
available on the market
the use of standard pitch will come
into force in China in 2016/17.
“For the use of high-temperature
pitch one requires heat-transfer media
that can reach temperatures of
up to 400 °C. We are currently evaluating
various heat-transfer media
with respect to their suitability and
are also working on a special project
with an external institute,” says
Mr Fiedler, adding that he does not
wish to reveal any further details
at the moment for competitive reasons.
■
Integration der Gattierungsrechnung
macht recycling noch effizienter
Um Aluminiumschrotte effektiv und
qualitätsgesichert in der laufenden Produktion
einsetzen zu können, ist eine
optimale Gattierungsrechnung unerlässlich.
Sie wird jedoch oft als Insellösung
betrieben, was Zeit bei der Einstellung
der gewünschten Qualitäten kostet.
Durch die intelligente Integration in ein
Produktionsmanagementsystem können
Aluminiumrecycler ihre Prozesse nun an
zentraler Stelle optimieren. Und entscheidende
Wettbewerbsvorteile erlangen:
Da alle Informationen zu jeder Zeit an
jedem Ort in Echtzeit zur Verfügung
stehen, kann mit einer schnellen und präzisen
Analyse der Schmelze die Zahl der
Nachlegierungszyklen deutlich gesenkt
werden. In der Praxis werden damit
Raten zwischen 1 und 1,5 erreicht. Das
steigert nicht nur die Durchsatzrate, sondern
optimiert auch Lagermanagement,
Energiebilanz und Einkauf. Das Ergebnis:
ein transparenter, maximal produktiver
Regelkreislauf und hochwertige Endprodukte
mit zuverlässiger Rückverfolgbarkeit.
Ständig steigende Energiekosten und der
Wunsch nach optimaler Ressourceneffizienz
haben sortenreine Produktionsabfälle zu einer
wichtigen Rohstoffquelle für die Metallindustrie
gemacht. Dies gilt insbesondere für Aluminiumschrotte,
denn mit einem Anteil von
etwa 20 Prozent an der weltweiten Gesamtproduktion
hat das Recycling von Aluminium
einen beachtlichen Stellenwert erlangt. Das
liegt insbesondere am enormen Einsparpotenzial:
Verglichen mit der Primärherstellung
braucht man dort im Schnitt 90 Prozent we-
Integrated charge and alloy calculation
makes recycling even more efficient
In order to effectively use and ensure
the quality of aluminium scrap in ongoing
production, optimum calculation of
charge and alloy materials is crucial. This
is often operated as an island solution and
takes time when it comes to setting the
required qualities. Thanks to intelligent
integration into a production management
system, aluminium recyclers can
now optimise their processes at a central
point, thus giving them an edge over
competitors. Now that all the information
is always available everywhere in
real-time, a fast and precise analysis of
the melt can reduce the number of alloying
cycles significantly. In practical
applications, average rates between 1
and 1.5 were in fact achieved. This not
only boosts the throughput rate, it also
improves warehouse management, the
energy balance and purchasing. The result
is a more transparent loop with maximum
productivity and high-quality end products
with reliable traceability.
The persistent rise in energy costs and demand
for optimum resource efficiency have made
sorted produced waste an important source
of raw material for the metals sector. This applies
particularly to aluminium scrap which,
accounting for around 20% of total global
production, has made aluminium recycling
extremely important. This is largely due to
the enormous savings potential. Compared to
primary production, recycling uses on average
90% less energy; far fewer difficult residual
materials are produced and, in terms of quality,
the final product cannot be distinguished
from newly produced aluminium.
On the other hand, it must be noted that
recycling scrap metal is a very complex process
that calls for outstanding organisation along
the entire process chain in order to arrive at
a high-quality, profitable and safe product.
This organisation has been picked up by PSI
Metals, an IT company based in Düsseldorf,
Germany, that specialises in production management
systems for the metals industry. By
integrating the central charge and alloy calculation,
the entire production process can be
optimised.
the optimum combination of input
materials makes all the difference
Regardless of the different sizes, alloys and
soiling of the aluminium scrap – whether it is
externally purchased scrap or scrap metal from
your own production waste which is to be recycled,
the aim is to produce a material that
features the alloy requested by the customer
and which precisely meets the respective requirements
and properties. What’s crucial
here is efficient organisation of the alloying
process based on the charge and alloy calculation.
At the same time, the chemical analysis
of the alloys in the melting furnace is a decisive
factor for the efficiency of the entire production
process. That is because precise measuring
results that have been generated quickly
58 ALUMINIUM · 9/2013

teChNOLOGy
Der integrierte Monitor liefert in Echtzeit alle relevanten Informationen
The integrated monitor supplies all relevant information in realtime
and directly are what make it possible to organise
the entire process chain in a more transparent
and efficient manner.
Integrated charge and alloy calculation offers
considerable potential for optimisation
and PSI Metals offers this in the form of its
Alloy Calculator. This not only controls the
alloy analysis, it has been integrated into the
PSI Metals production management system
so that all data related to organisation and
production, from the delivery of scrap to
warehouse management, are captured in realtime
and then used to perfectly monitor and
control charging and alloying. In this system,
the charge and alloy calculation serves as the
central reference and control variable for all
organisational and strategic production processes.
The sequence of individual work steps
is understood and visualised as a dynamic
loop. With each work step, the entire loop is
updated and all the information can be accessed
at any point in time. This rules out unnecessary
trips, misunderstandings and errors,
especially at critical interfaces, such as warehouse
management, production, laboratory or
purchasing. The necessary decisions can be
made faster, more flexibly and more precisely
on the basis of the latest information.
the first step: continuous
material tracking
In practical application, the advantages of
PSI’s solution become very clear. First of all,
the system records all scrap metal the minute
it is delivered or produced in your own production
(internal loop); in the next step, the
scrap metal is sorted and stocks are visualised.
In the long run, continuous material tracking
niger Energie; es fallen deutlich weniger problematische
Reststoffe an und das Endprodukt
ist qualitativ nicht von Hüttenaluminium zu
unterscheiden.
Diesen Vorteilen steht die Tatsache gegenüber,
dass die Wiederverwertung von Schrotten
sehr komplex ist und entlang der gesamten
Prozesskette höchste organisatorische Anforderungen
stellt, wenn am Ende ein hochwertiges,
rentables und sicheres Qualitätsprodukt
stehen soll. PSI Metals, ein in Düsseldorf ansässiges
IT-Unternehmen und Spezialist für
Produktionsmanagementsysteme in der Metallindustrie,
setzt genau hier an: Durch die
Integration der zentralen Gattierungsrechnung
wird der gesamte Produktionsprozess
optimiert.
die optimale Kombination der
einsatzstoffe macht den Unterschied
Unabhängig von den Stückigkeiten, Legierungen
und Verschmutzungsgraden des zu
verarbeitenden Aluminiumschrotts – ob überwiegend
fremder Schrott oder werkseigener
Fabrikationsabfall verwertet wird: Produktionsziel
ist ein Werkstoff, der die vom Kunden
jeweils gewünschte Legierung aufweist
und die entsprechenden Anforderungen und
Eigenschaften genauestens erfüllt. Dreh- und
Angelpunkt ist hierbei die effiziente Organisation
des Nachlegierungsprozesses auf der
Grundlage der Gattierungsrechnung. Zugleich
ist die chemische Analyse der im Schmelzofen
befindlichen Legierungen ein entscheidender
Faktor in Bezug auf die Effizienz der gesamten
Produktion: Je präziser die Messergebnisse
ausfallen, je schneller und gezielter sie
generiert werden, desto transparenter und
© Hydro Aluminium
effizienter kann die gesamte Prozesskette organisiert
werden.
Großes Optimierungspotenzial liegt hierbei
in einer integrierten Gattierungsrechnung, die
PSI Metals mit dem Alloy Calculator anbietet.
Dieser regelt nicht nur die Legierungsanalyse,
sondern ist in das Produktionsmanagementsystem
von PSI Metals so integriert, dass von
der Anlieferung des Schrottes über das Lagermanagement
bis hin zur Schmelze alle organisations-
bzw. produktionsrelevanten Daten
in Echtzeit erfasst und auf optimale Weise die
Gattierung überwacht und gesteuert wird. In
diesem System ist somit die Gattierungsrechnung
als zentrale Bezugs- und Regelgröße für
alle organisatorischen und strategischen Prozesse
der Produktion etabliert. Die Abfolge
einzelner Arbeitsschritte wird als dynamischer
Kreislauf begriffen und visualisiert, mit jedem
Arbeitsschritt wird der gesamte Kreislauf aktualisiert,
und alle Informationen sind zu jedem
Zeitpunkt eins zu eins abrufbar. So lassen
sich gerade an kritischen Schnittstellen wie Lagermanagement
/ Produktion / Labor oder Einkauf
Umwege, Missverständnisse und Fehler
vermeiden. Notwendige Entscheidungen werden
anhand jederzeit aktueller Informationen
schneller, flexibler und präziser getroffen.
der erste schritt: eine
lückenlose Materialverfolgung
In der Praxis zeigen sich die Vorteile der PSI-
Lösung sehr konkret. Zunächst erfasst das System
alle Schrotte im Moment ihrer Lieferung
oder ihrer Entstehung in der eigenen Fertigung
(interner Kreislauf); so kann im nächsten
Schritt eine saubere Sortierung und Visualisierung
der Lagerbestände erfolgen. Die lückenlose
Materialverfolgung ermöglicht auf lange
Sicht eine Optimierung des Lagerplatzes: Vom
Zeitpunkt der Lieferung an erfolgt eine klare
Zuordnung nach Legierungen, sodass spätere
Umsortierungen, die zu Vermischungen oder
zusätzlichen Verunreinigungen des Schrottes
führen können, vermeidbar sind.
Vor allem aber erleichtert es das zügige
Auffinden des gewünschten Materials. Geht
eine bestimmte Legierung in Produktion, so
hat der Staplerfahrer schnellen Zugriff: Ein
in den Gabelstapler integrierter Monitor informiert
online über die benötigten Legierungen.
Per Touchscreen kann sich der Fahrer
dann eine Übersicht über die Lagerbestände
verschaffen und erhält den entsprechenden
Schrottlagerplatz direkt angezeigt. Zielgerichtete
Transportaufträge und deren exakte Verfolgung
senken die Fehlerquote und sparen
definitiv Zeit. Der Fahrer muss nicht erst lange
nach einem irgendwo vermuteten Material
ALUMINIUM · 9/2013 59

teChNOLOGIe
Die Schmelze: Präzision beim Kernprozess zahlt sich aus
The melts: precision in the core process pays off
suchen, sondern kann sich durch die visuelle
Lagerdarstellung schnell orientieren und sofort
die richtige Box anfahren.
Eine ebenfalls in den Stapler integrierte
Waage verkürzt den Transport- und Chargiervorgang
– so geht keine Zeit durch eine
Extrafahrt zu einer Wiegestation verloren.
Ein wichtiger Aspekt der exakten Materialverfolgung
ist zudem die Klassifizierung eigener
Reststoffe (z. B. Kopf- und Fußschrotte, Besäumschrotte),
deren Zusammensetzung bekannt
ist und sich daher noch schneller in den
Recyclingprozess einbinden lassen.
Best Practice: ein durchschnitt
von 1,2 Nachlegierungszyklen
Je schneller die richtige Legierung erreicht
ist, umso weniger Nachlegierungszyklen sind
erforderlich, desto weniger Energie wird verbraucht
und umso besser ist die Ausnutzung
der Schmelzöfen. Zur Optimierung der Legierungsanalyse
liefert der Alloy Calculator
schnelle und präzise Ergebnisse, die wiederum
unmittelbar im Produktionsmanagementsystem
umgesetzt und genutzt werden. Nach nur
etwa 15 Minuten liegt das Analyseergebnis im
System vor, sodass unmittelbar entschieden
werden kann, welche Elemente der Legierung
noch zugefügt werden müssen. Diese Information
geht online und automatisch an den
Staplerfahrer, der dadurch innerhalb kürzester
Zeit die richtige Menge des Materials anliefert,
das zur Optimierung des Produktes
benötigt wird. Wert und Gewicht des gelieferten
Materials werden im System registriert,
die Verringerung des Lagerbestandes wird
automatisch gebucht. Auch der Zeitverlust
durch Übertragungsfehler bei manueller Steuerung
entfällt.
Präzise Analyseergebnisse, die umgehende
Neukalkulation des Materialeinsatzes, Informationen
in Echtzeit sowie der direkte Zugriff
auf das Materiallager ermöglichen es, den
Gattierungsprozess deutlich zu verkürzen und
die Zahl der erforderlichen Nachlegierungszyklen
zu senken: Eine Zyklusdauer zwischen
45 Minuten und 2,5 Stunden (je nach Legierung)
sowie ein Mittel von 1,2 Zyklen pro
Produktionsvorgang – diese Zahlen sprechen
für sich. Der entscheidende Gewinn: die signifikante
Steigerung der Durchsatzrate und die
damit verbundene deutliche Energieeinsparung
pro Schmelze. Denn durch die Verkürzung
der Zyklen verringert sich die Ruhezeit
der Öfen, in denen die noch unfertige Schmelze
auf Temperatur gehalten werden muss.
Durch die bessere zeitliche Planbarkeit aller
Abläufe lässt sich zudem der Produktionsplan
insgesamt straffen und eine bestmögliche
Auslastung der Öfen im Sinne eines effizienten
Energiemanagements erreichen.
strategischer einkauf und
effizientes Lagermanagement
© Hydro Aluminium
Auch Lagermanagement und Einkauf profitieren
von der integrierten Gattierungsrechnung
und einer präzisen Materialverfolgung. Durch
die Transparenz der Lagerbestände und der
jeweils vorliegenden Legierungen kann der
Einkauf punktgenau ermitteln, welche Zukäufe
erforderlich sind bzw. zu einem bestimmten
Zeitpunkt der Produktionsplanung erforderoptimises
space in the warehouse because
from the time the scrap metal is delivered
it is clearly allocated according to alloys, so
that later sorting, which could result in mixing
or additional soiling of the scrap, can be
avoided.
More importantly, however, the required
material can be found much faster. If a certain
alloy is to be used in production, the driver of
the fork lift truck will have no trouble finding
it. That is because a monitor integrated into
the fork lift truck informs the driver online
of the alloys needed. Using the touch screen,
the driver can then view all the stocks and
directly knows the location of the scrap metal
in question. Targeted transport jobs and their
precise tracking reduce error rates and certainly
save time. The driver no longer has to
search for material that is thought to be somewhere,
instead he can quickly find his way using
the warehouse display and drive directly
to the right box.
A weighing device also integrated into
the fork lift truck shortens the transport and
charging process since no time is lost due to an
extra trip to a weighing station. Another
important aspect of precise material tracking
is also the classification of your own rest
material (e. g. head and foot scrap, trimming
scrap) where its composition is known and can
hence be integrated faster into the recycling
process.
Best practice: an average of
around 1.2 alloying cycles
The faster the right alloy is reached the fewer
alloying cycles are needed and this means
less energy and better utilisation of the melting
furnace. In order to optimise the alloy
analysis, the Alloy Calculator delivers fast
and precise results which can then be implemented
and used directly in the production
management system. After just a quarter of
an hour, the analysis result is available so that
the operator can immediately decide which
elements of the alloy still have to be added.
The information goes online and is automatically
sent to the fork lift truck driver who can
then quickly deliver the correct quantity of
material needed to optimise the product. The
value and weight of the material delivered is
recorded in the system and the reduction in
stocks is automatically posted. This also means
no more time lost due to recording errors with
manual procedures.
Precise analysis results, immediate re-calculation
of the material input, information in
real-time as well as direct access to the materials
warehouse make it possible to shorten
60 ALUMINIUM · 9/2013

teChNOLOGy
the charge and alloy process and hence reduce
the number of alloying cycles required: One
cycle of between 45 minutes to 2.5 hours
(depending on the alloy) with an average of
around 1.2 cycles per production process –
these figures speak for themselves. The most
decisive benefit is the significant increase in
throughput rate and the huge energy savings
for each melt. That is because the fewer the
cycles, the less idle time for furnaces where
the unfinished melt has to be kept at a constant
temperature. Thanks to improved planning for
all steps of the process, the production plan
itself can be streamlined in order to achieve
the best-possible utilisation of the furnaces in
the interest of efficient energy management.
strategic purchasing and
efficient warehouse management
Both warehouse management and purchasing
also benefit from integrated charge and alloy
calculation and precise material tracking.
Thanks to transparent warehouse stocks and
the alloys available, purchasing can identify
precisely which purchases are necessary or
will become necessary at a certain point in production
planning. Double or incorrect orders
due to a poor overview of stocks and of where
material is located can now be largely ruled
out. On top of that, all of the scrap metal stored
in the warehouse is recorded with its specific
alloy values and can be quickly found. This
means that it is easier to calculate production
costs more precisely and the necessary production
workflows can be optimally planned.
Is it advisable to use your own scrap metal or
does certain scrap have to be purchased? Is it
cheaper to add pure elements or which scrap
price is acceptable? Strategic questions like
these can be specifically answered on the basis
of index data supplied by the production management
system and the Alloy Calculator.
Better traceability
Produktionsabfälle und Schrotte – Ausgangsmaterial beim Alurecycling
Starting material for aluminium recycling: production waste and scrap
The traceability of the materials used is a criterion
that is becoming increasingly relevant due
to the tightening of product liability legislation.
Production management makes it possible to
ensure that material can be traced. As a digital
archive, it documents the composition of the
materials produced right down to the scrap
metal used, thus providing a long-term, reliable
and continuous history. And this is where
the loop closes: the more you know about your
scrap stocks thanks to persistent material tracking,
efficient warehouse management and precise
analysis value, the more transparent your
product will be and the better it can be traced.
Conclusion: huge potential for
optimisation all along the line
The production management system with integrated
charge and alloy calculation is the key
to efficient planning and control of production
based on the latest actual situation and
requirements and thus opens up huge potential
for optimisation.
From an operator perspective, it becomes
clear that integration means huge benefits:
greater efficiency for charge and alloy calculation
has impacts on the entire process chain;
the potential for optimisation can be directly
passed on to all areas upstream or downstream
from the core process of the melt. Further,
the aluminium industry can shape its processes
in a more flexible manner so that it can respond
faster to many different demands. The
latter means savings in the most important resources,
i.e. material, time and energy. ■
© Fotolia
lich sein werden. Doppel- oder Fehlbestellungen
durch mangelnden Überblick über die
Bestände und über den Verbleib von Material
lassen sich weitgehend vermeiden. Und: Ist jeder
im Lager vorhandene Schrott mit seinen
spezifischen Legierungswerten hinterlegt und
schnell auffindbar, so lassen sich die Produktionskosten
einer Legierung preislich wie organisatorisch
besser kalkulieren und die notwendigen
Produktionsabläufe optimal planen. Ob
es ratsam ist, eigenen Schrott zu verwenden
oder ob bestimmter Schrott zugekauft werden
muss; ob es günstiger ist, reine Elemente zuzufügen
und welcher Schrottpreis akzeptabel ist
– solche strategischen Fragen lassen sich anhand
der Kenndaten, die das Produktionsmanagementsystem
inklusive Alloy Calculator
liefert, konkret beantworten.
Bessere rückverfolgbarkeit
Die Rückverfolgbarkeit eingesetzter Materialien,
ein Kriterium, das angesichts der Verschärfungen
des Produkthaftungsgesetzes immer
relevanter wird, lässt sich mithilfe des
Produktionsmanagements besser gewährleisten.
Als digitales Archiv dokumentiert es
langfristig und zuverlässig die Zusammensetzung
der produzierten Materialien bis zurück
zum eingesetzten Schrott in einer lückenlosen
Historie. Auch hier schließt sich ein
Kreislauf: Je besser die Kenntnis der eigenen
Schrottbestände durch konsequente Materialverfolgung,
ein effizientes Lagermanagement
und präzise Analysewerte, desto transparenter
das eigene Produkt und desto besser
seine Rückverfolgbarkeit.
fazit: hohes Optimierungspotenzial
auf ganzer Linie
Das Produktionsmanagementsystem mit integrierter
Gattierungsrechnung ermöglicht die
effiziente Planung und Steuerung der Produktion
auf der Grundlage tatsächlicher, aktueller
Gegebenheiten und Anforderungen und setzt
großes Optimierungspotenzial frei.
Aus Anwenderperspektive zeigt sich, dass
gerade die Integration den hohen Nutzen
bringt: Die gesteigerte Effizienz der Gattierung
wirkt auf die gesamte Prozesskette zurück;
das Optimierungspotenzial lässt sich
auf alle Bereiche, die dem Kernprozess der
Schmelze vor- und nachgeschaltet sind, unmittelbar
umlegen. Zudem kann die Aluminiumindustrie
ihre Prozesse flexibler gestalten
und schneller auf unterschiedlichste Anforderungen
reagieren. Letztlich bedeutet dies
Einsparungen der wichtigsten Ressourcen:
Material, Zeit und Energie.
■
ALUMINIUM · 9/2013 61

TECHNOLOGY
Turla targets equipment quality and
performance for customer success
Gutmann Group buys Turla new extrusion press – complete with all upstream and downstream equipment
Italian company Turla Srl, for more than
40 years a specialist in building aluminium
extrusion systems, has progressed
to be a world leader in this field. ALU-
MINIUM was most privileged to meet
recently with the company to learn more
about the past, present and future of the
well-known enterprise, together with its
continuing business success in securing
further project contracts.
ALUMINIUM: Turla is well known as a major
world player in extrusion production systems
– but can you outline some of the history and
heritage related to the business that have led
up to your enviable position in the industry?
Turla: Initially founded in 1967 in Brescia,
Lombardy, Northern Italy, the company was
first involved in heavy steel machinery. Subsequently
we began working in the aluminium
extrusion field in 1972, manufacturing
wrapping machines and complete packing
lines for extruded aluminium. The plant progressed
to designing and manufacturing single
machines for the extrusion process, including
pullers and walking beams. Within just a few
years Turla’s product catalogue covered the
entire extrusion production line, from the
billet heating furnace through to the ageing
oven. By the second half of the 1980s Turla
had established a reputation in Europe for the
quality of its products. During the late 1980s
and early 1990s we also progressed to become
one of the major suppliers of handling systems
to Hydro Aluminium, having built some 28
installations for this major organisation, and
in fact, the 29 th is in the pipeline for delivery
to Hydro Nenzing, Austria in 2014.
Today Turla is a well recognised partner
of other major international aluminium extrusion
companies, such as Constellium and
Sapa amongst others. We think that our work
approach over these 40 years has been firmly
supported and improved by the continuous
cooperation with these companies. In fact, we
consider our customers’ production managers,
plant operators and maintenance crew to be
our own engineers. This is because in reality,
it is through several years of cooperation with
these qualified professionals, that we have
been positioned to improve machines year on
year in terms of operation, maintenance and
reliability, all aimed at a short payback period,
Extrusion press entirely pre-installed at Turla facilities
greater productivity and a long service life.
What are your present locations and extent
of operations?
Turla is currently active at its two production
sites and further expansion is currently
underway with a new building – all three are
located in the Brescia region of Northern
Italy. 100% of our products are engineered
and manufactured in-house by experienced
Turla personnel. This also includes all related
hardware and software, designed and manufactured
by our daughter company TF Automation.
Turla site number 2, located in Paderno
Franciacorta, has been in operation since 1996
and hosts the headquarters, together with
engineering activities, sales, administration offices
and manufacturing of handling
systems. With a generous floor
space of over 9,000 square metres,
this facility houses all the work to
build machinery for aluminium extrusion
handling systems, including
all manufacturing stages such as engineering,
welding, machining, assembly and
dry testing.
Turla’s third site was completed in 2008
to provide additional production capacity
and its launch coincided with the start of the
company’s extrusion press manufacturing.
The ground floor of the new facility was purposely
designed to enable building complete
extrusion line installations and including dry
testing. This is a practice we use to start and
test the machines before we ship them to our
customers. This provides a great benefit both
for us and for clients by significantly minimising
the start-up phase at customers’ sites.
The new facility is also home to our daughter
company TF-Automation, which is active
in the production of hardware and software
for our extrusion systems and employs more
than 30 people covering different activities
such as electrical cabinet preparation, electrical
schematics, I/O list engineering, PLC
programming and even customer care. In fact
TF-Automation, through our Teleservice connection
to other Turla installations is able to
monitor our machine parameters 24/7 as well
as adjust and modify working cycles to ensure
optimum performance.
This feature is appreciated by
our customers since technical
parameters can readily
be viewed and possible problems
directly solved without
need to be physically at the
extrusion site.
Could you summarise the company’s overall
philosophy underpinning your success?
Our company policy can be simply summarised
by our motto: Only quality generates
quality. The word ‘Quality’ for us is not
only a mere word to be included in promotion
or certificates. Quality is not related to
machines but solely to professionalism – in
© Turla
62 ALUMINIUM · 9/2013

TECHNOLOGY
people, resources, methods, tools
and knowledge. This presents the
complete picture of what we can
offer. It is only possible to be truly
productive and satisfy customers
when real quality is cultivated
every day and in every activity that
is carried out in the company. We
deeply believe in this motto and
we continue to work towards constant
improvement. And this is true
also in an extrusion plant, because
quality profiles are not produced
through quality machines alone,
but also by quality people.
We are truly confident that all
the passion, the care and the precision
that we put in to our everyday
work produce the real essence of the topquality
machines that we design and build.
At the same time, we strongly believe – and
this is confirmed by the conversations that we
have every day with our customers – that high
quality profiles can only be produced through
high quality machines and this is our daily
target: making outstanding extrusion handling
systems that will produce defect-free, high
quality extrusions.
In conclusion, quality has always been a
very important factor for Turla and it is very
important to highlight that we were the first
and the only Italian company active in manufacturing
extrusion handling systems to obtain
ISO 9001 certification, which we did in 2003.
Could you outline typical examples of
Turla’s extensive product range?
Our machines have proven their ability to
guarantee minimal or zero equipment downtime.
Construction details and quality are not
a minor issue for us. This is why Hydro, Sapa,
Constellium and other major world players
have continued to select Turla systems for
their extrusion projects.
Why buy a cheaper machine, when a sixmonth
delay in production start-up can cost
you up to ten million euros in production
losses and then after five years most of the
equipment is ready to be scrapped?
We are open and ready every day for transparent
technical discussions with our customers
to consider relative machine comparisons,
which consistently show that Turla is the most
convenient choice that a customer can ever
make for their new machines. In other words
our machines are the least expensive in terms
of global and life cycle costs.
Additionally, we have always been known
for being able to ‘tailor a suit made-to-measure’.
This capacity derives predominantly from
working with clients who need customised
Press main cylinder forged as a single part, without welding
Water and air spray quench model QAH
and not standard production solutions – particularly
those that can meet the needs of advanced
customers in delivering the maximum
productivity and the optimum profitability
from their production lines. This approach to
design has resulted in innovative machines
being built primarily for ‘non-standard’ applications,
and in turn have become high performance
standard machines for primary extruders,
which we can now offer to the market
as longtime proven solutions.
For example, our air and water quenching
systems represent a must-have product for
every extruder involved in leading automotive
production. This is also the case, however,
for other equipment such as billet heaters, hot
billet saws, presses, pullers, stretchers, finishing
saws and basket transportation systems. At
the end of the day we are one of the few suppliers
able to supply a complete turnkey solution,
from billet through to profile
finishing, including the extrusion
presses. We offer all types of extrusion
systems, from ultra-light
profiles to those involved in the
production of large components,
such as for structural, railway and
aircraft applications.
Turla’s after-sales services and
customer care activities are supported
by our Teleservice mentioned
earlier and the company’s
capacity to ship spare parts
promptly around the world is well
recognised.
How have the company’s evolution
and developing technologies
continued to support the business?
Turla has organised itself to accomplish
continuous improvement both in designing
and manufacturing point of view, trying to get
the best value from the professional growth
of its employees and the best practices applied
in the manufacturing operations. For example
we have developed very powerful calculation
tools for profiles cooling simulations and now
this technology is definitely a major competitive
advantage when offering quenching systems
all over the world.
Another significant improvement in the last
ten years is the particular care we devote to
the electrical hardware and software preparation
of the machines. These activities represent
for Turla a point of strength in the engineering
and consolidation of machines reliability.
The fact that everything is made, inspected
and proved in-house before shipment to the
ALUMINIUM · 9/2013 63

TECHNOLOGY
Stretcher tailstock
customer is a further indication of our quality,
spirit and dedication to our systems.
Importantly, we ensure that safety and
reliability of our machines are in-built and
critically linked. A reliable machine cannot be
unsafe, and a safe machine cannot deliver a
low productivity for customers. All of our machines
are therefore supplied with automatic
controls that maximise their reliability and the
safety in operation.
How important are new ideas, innovations
and developments to Turla, in both technology
and business?
Turla’s main thrust in design work involves
continuous improvement of our existing machinery
range. Regular interfacing between
our own engineers and customers provides
vital feedback for us to understand how machines
can be improved and even more closely
aligned to individual customer needs. Overall,
the most significant innovations in the
past ten years have centred on three products
that have been very well received
by the extrusion industry:
Turla’s STeP 5 gas-fired billet
heater offers the lowest gas consumption
and atmospheric pollution
levels possible worldwide:
This heater, with a proved thermal
efficiency of 81%, is by far the
most efficient device of its type
on the market in terms of operational
costs, maintenance and CO 2
pollution. Our customers have to
deal every day with rising energy
costs and new carbon taxes that
clearly disadvantage less efficient
extrusion plants where old and
excessively polluting equipment is
in operation. We have been frequently chosen
in recent years by customers looking for
products to help them in dramatically reducing
their environmental impact. In just one example,
a STeP 5 billet heater installed to replace
an old heater has resulted in a reduction of
CO 2 emissions of around 380 tpy, equivalent
to a reduction in emissions from 150 medium-size
cars! This figure clearly illustrates the
huge potential for lowering atmospheric pollution.
The Turla website – translated into English,
Russian and German languages – enables all
customers to calculate the annual tonnages of
CO 2 emissions that can be avoided by installing
a Turla STeP 5 in their extrusion lines.
Intensive quench QAH Air / Water spray:
Over the past decade this equipment has been
installed with success in the most advanced
extrusion facilities in Europe, where the production
focus is mainly on automotive profiles.
This machine, greatly appreciated for its high
Flying cut double puller, model DPC-TV
cooling power and flexibility, using both water
spray and air, is designed to suit the most demanding
cooling cycles required by specified
profile tolerances.
Extrusion press: The recent order from
Nordalu, a plant in the Hermann Gutmann
Group Neumunster, Germany, marks the start
of Turla’s penetration in central Europe, including
the supply of extrusion presses. The
Turla 18FR7 model, denoting 18-MN press
force with front-loading design and 240 bars
for 7-inch billets, requires no special foundations
since there is no force on the ground due
to precise engineering design and tolerances.
All main parts are forged and the whole machine
is delivered pre-stressed to the customer.
The press will be equipped with the Turlaengineered
‘Eco + Logic’ package which delivers
a considerable energy saving of some
90,000 euros worth of electricity per year.
Only the energy required for extrusion will
be used, the rest will be saved as a result of
a smart software program entirely developed
by Turla through five years of investigation in
SW development.
All systems will be fully pre-installed at
Turla: the STeP 5 , the HLS-7 hot billet saw and
18FR7 extrusion press model will be fully assembled
at the company’s Brescia facility in
early 2014. Hot profiles will actually be extruded
in the works, prior to shipment of the
machinery to the customer in Germany for
on-site installation. Turla is also organising a
‘Press Open Week’ at this time, when interested
world-class extruders will be invited to
attend.
Does Turla enjoy any special partnership
relationships with its extruder customer
base?
Leading extrusion operations have recently
chosen Turla as partner for their most strategic
projects. Orders from such well-known
companies as Constellium Singen and Nordalu
in Germany, Hydro Nenzing
in Austria, Sapa Profiles Kft in
Hungary and Bonnell Aluminum
in the United States, show clearly
that high technology extruders
are seeking high technology suppliers.
But, one of the things that
we pride ourselves on even more
in our day by day business is that
our customers return to us for every
new project, and this is absolute
proof of true customer satisfaction.
We are really proud to have customers
that have purchased our
products repeatedly for more than
25 years. In some factories it is easy
to see, in the space of just a few
64 ALUMINIUM · 9/2013

TECHNOLOGY
square metres the complete history
of Turla machinery – equipment
built in the late 1970s and early
1980s is still working perfectly
alongside latest solutions we have
installed in recent years.
What new marketing innovations
does the company exploit?
Turla employs all the modern
communication means available
but we try to avoid impersonal
communication since the very valuable
information involved must
be properly communicated securely
to our customers and potential
customers. We have also made
available in the secure area of our
website a series of interactive tools
that provide useful and interesting
tips for customers when they are considering
a new extrusion handling system.
Could you point to any specific recent
project references in Europe that particularly
stand out?
Amongst examples of recent projects Turla
has carried out in the European region, we
can highlight four in particular.
Constellium Singen: In what is probably
the most important project in Germany to
date for Turla in the last ten years, we have
recently concluded the final commissioning
of the extrusion handling system for the customer’s
new 44-MN press, entirely dedicated
to the production of automotive parts. Turla
was awarded the contract in March 2012 for
the supply of a complete system downstream
Finishing saw
The most efficient and least polluting billet heater
of the press, to be supplied with an innovative
and unique intensive air / water spray quench,
flying cut puller, 120-tonne stretcher and finishing
saw. The installation project has been
concluded with complete success for which we
received compliments from the Constellium
Singen management.
Hydro Nenzing: We were awarded an order
earlier this year for a 16-MN press extrusion
handling system. This project is an endorsement
of all our previous first-class work
with Hydro Nenzing where we installed the
first Turla system in 1995. Originally equipped
with the Pinze System, invented by Turla,
the system is still perfectly operational. Since
then we have always been a reliable partner
for this plant that is one the most productive
facilities in the entire Hydro
Group in terms of productivity and
quality.
Sapa Profiles kft Szekesfehervar:
We recently received an order
for the modernisation of the 35-
MN extrusion handling system at
Sapa’s biggest extrusion plant in
Europe. The contract will mainly
comprise an intensive air and water
spray quench system (model
QAH) and a double puller flying
cut machine, all with very stringent
requirements in terms of productivity
and final product quality.
Nordalu Neumunster – Gutmann
Group: As reported above
we have recently received the order
for a complete extrusion handling
system consisting of our low consumption billet
heater SteP 5 , a Turla 18-MN extrusion press and
a complete handling system through to the
profile stacker. We are very pleased that an
important company such as Gutmann has honoured
us with such an important order that
represents a critical development point for the
group’s Nordalu site in Neumunster.
Looking to the future – how do you see
the current status and trends in aluminium
extrusion?
We think that in the coming years the entire
extrusion market will undergo an extensive
reorganisation. As part of this, unfortunately,
increased competition will lead to the
shut-down of non-competitive sites. This could
be viewed generally as a negative thing due to
contraction of the market but we are totally
confident that companies that have invested
considerably in terms of new products and
new machines will grow their business – and,
of course, we will be there to support them
with our innovative products.
Does the company have any other points
or observations on the industry in general that
you would like to stress?
Our company is medium-sized and familyowned
and in fact the owners take an active
part in the management. We bear a great responsibility
in proudly displaying the ‘Turla’
name on all our machines – presses, pullers,
heaters and handling systems – the same kind
of responsibility taken in the past by worldfamous
Italian makers of beautiful, handcrafted
cars, such as Ferrari, Lamborghini and
Maserati. This is Turla and our passion is profoundly
interwoven with technological improvement
on a daily basis, each and every
day.
Many thanks for your time and most interesting
information.
■
ALUMINIUM · 9/2013 65

TECHNOLOGIE
Belte AG – Spezialist für die Wärmebehandlung von Aluminiumbauteilen
„Wir sind ständig bestrebt, Prozesse weiterzuentwickeln“
Die Belte AG aus Delbrück ist ein anerkannter
Spezialist im Bereich der Wärmebehandlung
von Aluminiumbauteilen.
Das Unternehmen agiert als reiner
Dienstleister und zeichnet sich durch seine
hohe Kompetenz bei der Entwicklung
innovativer Wärmebehandlungsverfahren
und Abschreckmedien aus. ALUMINIUM
sprach mit dem Gesellschafter und Vorstand,
Markus Belte, über die Entwicklung
des Unternehmens.
Belte AG – Specialist in the heat treatment of aluminium components
“We constantly strive to develop our processes further”
Die Belte AG ist fast ausschließlich für die
Automobilindustrie tätig. Praktisch alle deutschen
Autohersteller zählen zum Kundenkreis,
wenn es um die Wärmebehandlung von
Motoren, Fahrwerks- oder Strukturbauteilen
aus Aluminium geht. Gegründet hat Markus
Belte seine Firma 1998 – praktisch als Ein-
Mann-Unternehmen und mit dem Knowhow
der Polymerabschreckung von Kurbelgehäusen,
die seinerzeit für einen Premiumhersteller
im kleinen Rahmen erprobt werden sollte.
Heute beschäftigt das Unternehmen rund 180
Mitarbeiter.
Markus Belte kommt ursprünglich aus dem
Bereich der Produktentwicklung. Für einen
amerikanischen Konzern entwickelte er chemische
Produkte für die Wärmebehandlung
von Stahl (Härteöle, Polymerlösungen) und
Kühlschmierstoffe zur mechanischen Bearbeitung
von Aluminiumteilen. Anfang der
1990er Jahre wurden dann erste Produkte
für die spannungsarme Wärmebehandlung
von Automobilkomponenten aus Aluminium
entwickelt. Ziel damals war es, Probleme mit
der Rissbildung bei Kurbelwellenlagersitzen
zu beheben.
Dazu wurde für den Abschreckprozess
nach der Wärmebehandlung ein wasserlösliches
Polymer entwickelt. Belte erläutert die
Vorteile: „In dem Moment, wo das Bauteil in
diese Lösung eintaucht, verdampft das Wasser
an der Oberfläche und der Polymerfilm legt
sich praktisch wie Honig auf die Oberfläche.
Der Film ist an den dünneren Querschnitten
dicker als an den dickeren Querschnitten. Die
Wärme im Bauteil versucht zu entweichen,
der Film wird abgesprengt und bildet sich in
Bruchteilen einer Sekunde sofort wieder neu.
Dieser sich kontinuierlich wiederholende
Prozess sorgt dafür, dass die dünnwandigen
Bereiche ähnlich schnell abkühlen wie die
dickwandigen. Man erhält so während der
Abkühlphase einen Temperaturausgleich
Wärmebehandlungsanlage für Gussteile
Belte AG in Delbrück is a recognised
specialist in the field of heat treatment
for aluminium components. The company
is active as a pure service provider and is
noted for its high competence in the development
of innovative heat treatment
methods and quench media. ALUMIN-
IUM spoke to the managing proprietor
and CEO, Markus Belte, about the
development of the company.
Almost all of the activity of Belte AG relates
to the automobile industry. Virtually all the
auto manufacturers in Germany are among
its customers when they need aluminium
engines, chassis components or structural
components to be heat treated. Markus Belte
founded his company in 1998 – virtually as a
one-man company, and with know-how about
the polymer quenching of crank-cases, which
at the time were being tested for a premium
manufacturer on a small scale. Today the
company employs around 180 people.
Markus Belte originally came from the sector
of product development. For an American
company he developed chemical products for
the heat treatment of steel (hardening oils,
polymer solutions) and coolant lubricants
for the mechanical machining of aluminium
components. At the beginning of the 1990s
the first products were developed for the
low-stress heat treatment of aluminium auto
components. The problem at the time was to
eliminate crack formation in crankshaft bearing
seats.
For this, for the quenching process after
heat treatment a water-soluble polymer was
developed. Mr Belte explains the advantages
thus: “At the instant when the component
Markus Belte
Heat treatment plant for castings
© Belte AG
66 ALUMINIUM · 9/2013

TECHNOLOGY
is immersed in the solution, the water evaporates
at the surface and a polymer film forms
almost like honey over the surface. The film
is thicker over thin cross-sections than over
thicker cross-sections. The heat in the component
tries to escape and the film becomes
detached but re-forms again in fractions of
a second. This continually repeated process
ensures that the thin-walled areas cool at a
similar rate to the thick-walled ones. So during
the cooling phase the temperature in the
component is equalised. Thanks to this very
uniform cooling the stress level in the component
is very low, so there is a large margin, for
example, in relation to the yield strength.”
At the time, Belte’s aim was to market the
polymer to heat treaters. However, since at
the time there were no service providers who
wanted to heat treat aluminium components
with polymer, after
some hesitation and
with encouragement
from some car manufacturers
he decided to
begin heat treatment
himself. The decision
to do this and the resulting
inception of the
company are another,
partly adventurous
story we cannot go into
detail here.
The first two years
after the company’s
foundation were still
marked by small beginnings
with very few
workers, and with orders
mainly from Audi
(for the A2 model of
that time) and BMW;
over the next few years
from 2003 Belte expanded by works enlargement,
new production locations and company
takeovers. As is known the financial crisis of
2008/09, which seriously affected the automobile
industry, was also bad news for foundries
and other supplier industries – and Belte
too experienced from one month to the next
an extreme collapse of orders and payment
default because of insolvency on the customer
side. However, thanks to a capital increase by
bringing in financial investors from Bahrain
and to the sale of companies acquired only a
few years earlier, Belte AG was able to overcome
the financial and economic crisis.
At present the company is working at full
capacity, running four shifts seven days in the
week, and this despite the declining registration
figures in Europe for passenger cars. This
im Bauteil. Durch die sehr gleichmäßig Abkühlung
ist das Spannungsniveau im Bauteil
sehr gering, wodurch sich eine große Reserve
zum Beispiel auf die Streckgrenze bezogen
ergibt.“
Beltes Ziel seinerzeit war, das Polymer an
Wärmebehandler zu verkaufen. Da es damals
jedoch keinen Dienstleister gab, der die Wärmebehandlung
von Aluteilen mit Polymer
durchführen wollte, entschloss er sich nach
anfänglichem Zögern und dem Zuspruch von
Autoherstellern, in die Wärmebehandlung
einzusteigen. Die Entscheidung dazu und die
sich daraus ergebenden unternehmerischen
Anfänge wären eine eigene, zum Teil abenteuerliche
Geschichte wert, auf die hier jedoch
verzichtet werden muss.
Waren die ersten beiden Jahre nach Firmengründung
noch von kleinen Anfängen mit
Charge mit Gussteilen vor Abschreckung im Polymerbad
Batch of castings, ready for polymer quenching
wenigen Mitarbeitern geprägt, und von Aufträgen
vor allem für Audi (für das damalige
A2-Modell) und BMW, expandierte Belte in
den Folgejahren ab 2003 durch Werkserweiterung,
neue Produktionsstandorte und Firmenübernahmen.
Die Finanzkrise 2008/09,
die die Automobilindustrie massiv erfasste,
zog bekanntermaßen Gießereien und andere
Zulieferindustrien arg in Mitleidenschaft –
und auch Belte erlebte von einem Monat auf
den nächsten einen extremen Auftragseinbruch
und Zahlungsausfälle aufgrund von
Insolvenzen auf Kundenseite. Dank einer
Kapitalerhöhung durch Einbeziehung von Finanzinvestoren
aus Bahrain und des Verkaufs
der wenige Jahre zuvor erworbenen Firmen
konnte die Belte AG die Finanz- und Wirtschaftskrise
jedoch überstehen.
Derzeit arbeitet die Firma auf Hochtouren:
vierschichtig, sieben Tage in der Woche –
trotz der in Europa rückläufigen Zulassungszahlen
bei Pkw. Auch ein Zeichen dafür, dass
der Aluminiumleichtbau im Automobil weiter
auf dem Vormarsch ist – nicht zuletzt
dadurch, dass der Gießprozess mit anschließender
Wärmebehandlung komplexe, multifunktionelle
Bauteile ermöglicht, die früher
aus vielen separaten Einzelkomponenten teuer
zusammengefügt werden mussten.
„Aufhängung und Chargierung der
Bauteile von großer Bedeutung“
Kerngeschäft und Kernkompetenz des Unternehmens
sind heute wieder die Wärmebehandlung
und Entwicklung innovativer Wärmebehandlungsverfahren.
„Punktuell kommt
auch die Legierungsentwicklung mit ins Spiel,
weil Legierung und erfolgreiche Wärmebehandlung
zwei Seiten einer Medaille sind.
Darüber hinaus bieten wir auch mechanische
Bearbeitungen an, zum Beispiel bei Strukturbauteilen.
Bei Fahrwerksteilen führen wir
neben der Wärmebehandlung auch eine Röntgen-
und Rissprüfung durch“, so Belte.
Bei Strukturbauteilen ist die mechanische
Bearbeitung am weitesten fortgeschritten. Die
Teile kommen aus der Gießerei, werden bei
Belte entgratet, lösungsgeglüht und abgeschreckt,
automatisch gerichtet, warmausgelagert
und mechanisch bearbeitet, schließlich
werden Helicoils (Drahtgewindeeinsätze) und
andere Elemente montiert. Die Bauteile werden
noch KTL-beschichtet (KTL = kathodische
Tauchlackierung), anschließend verpackt
und verschickt.
Bei der Wärmebehandlung inklusive Abschreckung
geht es immer um die Faktoren
Streckgrenze, Bruchdehnung, Zugfestigkeit,
Eigenspannung und vermehrt auch Korrosionsbeständigkeit,
die sich durch Wärmebehandlung
beeinflussen lassen. Neben der Anlagentechnik,
Temperatur- und Zeitführung
sowie Abschreckung spielen die Warenträger
eine wichtige Rolle für die optimale Wärmebehandlung.
„Wenn ich Strukturteile oder
Druckgussteile auf 460 bis 490 °C aufheize,
nähere ich mich einem Temperaturbereich,
wo die Bauteile anfangen, sich plastisch zu
verformen. Daher kommt ihrer Aufhängung
und Chargierung eine große Bedeutung zu.
Wir haben uns viel Knowhow im Bereich der
Warenträger erarbeitet und Lösungen entwickelt,
wie die Bauteile im Ofen beschickt und
fixiert werden müssen, sodass ein möglichst
geringer Verzug auftritt“, sagt Belte.
Wie oben bereits skizziert, ist auch der
Abschreckprozess wichtig, damit die Bau-
ALUMINIUM · 9/2013 67

TECHNOLOGIE
teile möglichst gleichmäßig abkühlen. Als
Abschreckmedien kommen Luft, Wasser
und Polymer infrage. Welche Abschreckung
gewählt wird, hängt vom Bauteil ab, von
seiner Geometrie und den mechanischen Eigenschaften,
die erzielt werden sollen. Die
Polymer-Abschreckung ist beispielsweise für
komplexe Bauteile wie Kurbelgehäuse interessant.
Strukturteile wie Längsträger, die eine
große Oberfläche bei vergleichsweise geringer
Masse aufweisen, lassen sich gut mit Luft
abschrecken. Luftkühlung bei Belte heißt
HISAQ (High Speed Air Quenching), also
Luftabschreckung bei hoher Geschwindigkeit.
Belte hat diese Entwicklung für die Wärmebehandlung
von Kokillenguss- und Druckgussteilen
im Jahr 2003 zum Patent angemeldet.
Entwicklungsarbeiten mit Strahlungswärme
statt Luftumwälzung
Typischweise wird bei der Wärmebehandlung
mit Konvektion gearbeitet. Die Öfen sind so
aufgebaut, dass der Ofenraum per Luftumwälzung
aufgeheizt wird und die Bauteile
mit der heißen Luft in Kontakt kommen.
Das Unternehmen erprobt derzeit ein neues
Verfahren, bei dem die Bauteile direkt durch
Infrarotstrahler bestrahlt werden. „Auf diese
Weise lassen sich die Bauteile mit sehr hoher
Geschwindigkeit punktgenau auf Temperatur
bringen. Praktisch in wenigen Minuten“, so
Dan Dragulin, Leiter F & E bei der Belte AG.
Mit solchen Versuchen für Audi wurde bereits
vor drei Jahren begonnen.
Bei der Wärmebehandlung geht es immer
um mechanische Eigenschaften, aber auch um
Kosten. „Bei einem großen Ofenraum mit
Konvektionserwärmung dauert die Aufwärmphase
45 Minuten und länger, zum Beispiel
auf einer Durchlaufanlage für Zylinderköpfe.
Mit der Infrarotaufheizung haben wir es in
Versuchsanordnungen geschafft, solche Bauteile
innerhalb von sieben Minuten auf Temperatur
zu bringen. Ich kann so nicht nur die
Verweilzeit im Ofen verkürzen, sondern habe
durch die schnellere Aufheizung noch bessere
mechanische Eigenschaften“, hebt Belte hervor.
Zu den Versuchsergebnissen an einem
Strukturgussteil für Audi siehe nachfolgenden
Bericht.
Mit diesem Verfahren befindet sich Belte
noch im frühen Versuchsstadium. Ob und
in welcher Form diese Methode in Zukunft
marktfähig wird, ist noch nicht ausgemacht.
Die Entwicklungsarbeiten daran aber zeigen,
„dass wir nicht der klassische Dienstleister
sind, der Wärmebehandlung nach Vorschrift
macht, sondern ständig bestrebt sind, Prozesse
weiterzuentwickeln“, betont Belte. ■
Überwachung der automatischen Prozesse der Belte AG
Controlling automatic processes at Belte AG
is yet another sign that lightweight construction
with aluminium in automobiles is advancing.
Not least, because the casting process
with subsequent heat treatment enables the
production of complex and multi-functional
components which previously had to be expensively
assembled from several separate
individual components.
“The jigging and charging of the
components is very important”
The company’s core business and competence
is still today heat treatment and the development
of innovative heat treatment methods.
“Now and then alloy development is also involved
since the alloy and its successful heat
treatment are two sides of the same coin.
Moreover, we also offer mechanical machining,
for example of structural components. For
Bearbeitung eines Strukturbauteils
chassis components, besides heat treatment we
also carry out X-ray and crack testing,” says
Mr Belte.
Mechanical machining is most advanced in
the case of structural components. The parts
come from the foundry, they are deburred at
Belte, then solution-annealed and quenched,
automatically straightened, artificially aged
and mechanically machined. Finally helicoils
(wire-wound inserts) and other elements are
fitted. The components are then CIL-coated
(CIL = Cathodic Immersion Lacquering),
packed, and sent off.
In heat treatment and quenching the critical
factors are always yield strength, fracture
strength, tensile strength, internal stresses
and to an increasing extent also corrosion resistance,
all of which are influenced by heat
treatment. Besides plant technology, temperature
and time control and quenching, the
supporting jigs also
play an important part
for optimum heat treatment.
“When we heat
structural components
or castings to 460 to
490 °C, we are approaching
a temperature
range in which the
components begin to
deform plastically. So
the way they are jigged
and charged is very
important. We have
developed a great deal
of know-how about
the supporting jigs and
worked out solutions
about how to load the
components into the
furnace and fix them
in it, to ensure the least
Machining a structural component
68 ALUMINIUM · 9/2013

TECHNOLOGY
possible distortion”, says Mr Belte.
As already outlined earlier, the quenching
process is also important if the components
are to cool as uniformly as possible. The
quench media used are air, water and polymer
solutions. Which quenching media are
chosen depends on the component, its geometry,
and the mechanical properties to be produced
in it. For example, polymer quenching
is interesting for complex components such
as crank-cases. Structural components such
as longitudinal support members, which have
a large surface area with only comparatively
low mass, can be effectively air-quenched. At
Belte air cooling is called HISAQ (High Speed
Air Quenching), i.e. quenching in air at a high
rate. In 2003 Belte applied for a patent for this
development for the heat treatment of gravity
and pressure diecast components.
Development work on radiated
heat instead of air circulation
Typically, heat treatment is carried out by
convection. The furnaces are designed so that
the furnace chamber is heated by air circulation
and the components come in contact with
the hot air. At present the company is testing
a new method in which the components are
irradiated directly by infra-red radiation. “In
this way the components can be brought to
temperature very quickly and with pinpoint
accuracy: almost in a few minutes,” says Dan
Dragulin, head of R&D at Belte AG. Such
tests started for Audi already three years ago.
The important factors in heat treatment
are always mechanical properties, but also the
cost. “In a large furnace chamber with convection
heating the heat-up phase takes 45
minutes or more, for example in a continuous-throughput
unit for cylinder heads. With
infra-red heating, in test runs we managed to
bring such components to temperature within
seven minutes. In this way I can not only
shorten the dwell time in the furnace, but
achieve even better mechanical properties
due to the rapid heating,” stresses Mr Belte.
For the test results on a structural casting for
Audi, see the following report.
This process is still at an early stage of testing.
Whether and in what form the process
will in the future become marketable, is not
yet clear. However, the development work
so far indicates “that we are not a classical
service provider which carries out heat treatment
according to specification, but that we
always strive to develop our processes further,”
stresses Mr Belte.
■
Infrared heat transfer for thin-walled aluminium automotive castings
A novelty in the field of aluminium high pressure die casting
demonstrating the high versatility of aluminium as all around material
D. Dragulin, M. Belte, Belte AG
Fig. 1: Casting exposed to IR – between arrows: the zone under direct exposure
to radiation; distance between casting and IR-module: left: 10 cm, right: 30 cm
Fig. 2: Inappropriate position of the casting within the IR-module
© Belte AG
Preamble
The use of infrared radiation in the field of
aluminium processing enables easier automation
and control of the heat transfer processes
and contributes to productivity enhancement.
The electrical hardware of the
infrared module allows for drastic improvements
in the efficiency factor of the industrial
equipment used for aluminium processing,
while also reducing the pollution degree.
Dr. Dimitrie Popescu, Associate Professor, Old
Dominion University, Norfolk, Virginia, USA
Abstract
The application of infra-red radiation to heat
treatment of thin-walled aluminium high pressure
die castings is a process that is in the
early stages of its development. The objective
of the experiment presented here was to analyse
the heating rate of the casting and to study
its corresponding mechanical properties. All
experiments were realised using Audi-structural
castings.
Experimental conditions
The casting process was realised by Trimet.
• IR module
Ground coverage: 108 kW
• Casting
• Weight: 2.5 kg
ALUMINIUM · 9/2013 69

TECHNOLOGY
TECHNOLOGIE
Fig. 3: Influence of various operating conditions on the heating rate – not
coated
red: warm start in a encased module – 3.39 °C/s between 40 °C and 470 °C
green: warm start – 2.39 °C/s between 40 °C and 470 °C
blue: cold start – 1.84 °C/s between 40 °C and 470 °C
black: cold start and an inappropriate position of the casting within the
IR-module – 0.78 °C/s between 40 °C and 470 °C
Fig 4: Influence of the state of the surface on the heating rate;
warm start in a partially encased module
red: not coated – 2.85 °C/s between 40 °C and 470 °C
green and blue: two different coatings – 3.84 °C/s
respectively 3.94 °C/s between 40°C and 470°C
• Weight of the zone under direct
exposure to radiation: 1.5 kg
• Surface of the zone under direct exposure
to radiation: 0.078 m 2 per side
• Wall thickness of the zone under direct
exposure to radiation: 3-5 mm.
Fig. 2 presents an inappropriate position of
the casting within the IR-module; this leads
to a massive loss of the heating rate (see Fig.
3) and as consequence to a corresponding
reduction of the productivity.
The influence of various operating conditions
on the heating rate is shown in Fig. 3.
After the heating process the castings were
submitted to both a forced air and water cooling
and to a subsequent overaging (see Figs
4-5).
Experimental results
Under the oversimplification: merely the
zone under direct exposure to radiation will
be taken into consideration. Instant power
consumption was 8.42 kW per side
The mechanical properties (average of four
tests) are presented in Table 1.
Conclusion and
future prospects
The obtained mechanical
properties are more
than encouraging.
The design of the
IR-module is very
important for the optimisation
of the heat
transfer process. Modern
IR equipment can
be adapted to the casting
geometry.
Acknowledgement
The authors would like to thank Audi, Heraeus,
LOI-Italimpianti and Trimet for their
support.
as cast air cooling water cooling
Rp0.2 [MPa] 154 120 223
Rm [MPa] 301 214 300
At [%] 7.6 12.6 7.2
Heating regimes correspond to the red curve in Fig. 4
Table 1: Mechanical properties
References
Fig 5: Overaging (convection kiln)
[1] C. Samoila, L. Druga, L.Stan, Cuptoare si Instalatii
de Incalzire, EDP, Bukarest, 1983.
Authors
Dr. Dan Dragulin is head of Research and Development
at Belte AG, Delbrück, Germany.
Markus Belte is CEO of Belte AG, Delbrück, Germany.
Suppliers Directory – for your benefit
On pages 84 to 97, leading equipment suppliers to the aluminium industry present their
product portfolios and ranges of services. Take advantage of this useful information.
70 ALUMINIUM · 9/2013

TECHNOLOGY
Vom 14. bis 16.
Januar kommen
erneut Druckguss-
Spezialisten aus
ganz Europa zur Euroguss-Messe nach Nürnberg,
um sich über Produktneuheiten und
Trends zu informieren. Zum aktuellen Stand
der Anmeldungen und zur erwarteten Ausstellerzahl
erklärt Heike Slotta, Leiterin Veranstaltungen
bei der Nürnberg Messe GmbH:
„Die Akquise läuft sehr gut. Wir haben den
Anmeldestand der Vorveranstaltung jetzt
schon (redaktionelle Anm.: Stand Juli) erreicht.
Viele Unternehmen haben ihre Standflächen
vergrößert, weil die Euroguss für sie
eine wichtige Plattform zur Kontaktpflege
und zum Aufbau von neuen Geschäftsbeziehungen
ist. Ich rechne mit rund 400 Ausstellern
auf der Messe im Januar. Auch die internationale
Beteiligung auf Ausstellerseite
entwickelt sich sehr erfreulich, zum Teil auch
aus Ländern, die bisher noch nicht so zahlreich
auf der Messe waren, wie die Türkei.
Besonders stark vertreten sind Unternehmen
aus Italien und Schweden, die mit je einem
Gemeinschaftsstand dabei sind.
Zu den Angebotsbereichen, die auf der
Euroguss zu sehen sind, sagte sie weiter:
„Das Messeangebot bildet die gesamte Druckguss-Wertschöpfungskette
ab – von der Technik
über die Prozesse bis hin zu den Produkten.
Die Aussteller sind Druckgießereien,
also die Hersteller von Gussteilen und Komponenten,
sowie deren Zulieferer, Ausrüster
und Dienstleister. Sie zeigen Druckgusstechnologie,
Angebote zur Nachbehandlung von
Gussteilen, Trenn- und Betriebsstoffe, die im
Herstellungsprozess notwendig sind, Möglichkeiten
der Qualitätskontrolle, Steuerungsund
Antriebstechnik sowie das weite Feld der
Software.“
you‘re in good hands ...
Euroguss 2014: „Anmeldestand der
Vorveranstaltung bereits erreicht“
Die Euroguss findet 2014 zum zehnten Mal
statt. Zu den Highlights der Jubiläums-Veranstaltung
sagte sie: „Dieses Messejubiläum
möchten wir zusammen mit allen Ausstellern
und Besuchern feiern und organisieren aus
diesem Anlass eine Sonderschau, die die Entwicklung
des Druckgusses beleuchtet und
den Bogen von der Vergangenheit bis in die
Euroguss 2014: “Level of applications
for previous event already reached”
Zukunft spannt. Sie ist während der Messe
im Eingangsbereich zu sehen. Dazu feiern
wir natürlich eine ordentliche Geburtstagsparty
und planen noch ein paar weitere Jubiläumsaktionen.
Darüber hinaus gibt es natürlich
wieder die beliebte Sonderschau „Forschung,
die Wissen schaf(f)t“, den Internationalen
Deutschen Druckgusstag mit spannenden
Fachvorträgen von Experten für Experten
sowie die Verleihungen des Internationalen
Aluminium-Druckguss-Wettbewerbs
und des Zinkdruckguss-Wettbewerbs. ■
From 14 to 16 January 2014 die casting specialists
from all over Europe will be visiting
the Euroguss trade fair in Nuremberg to update
on new products and trends. Regarding
the current level of applications and the expected
number of exhibitors, Heike Slotta, director
Exhibitions at Nürnberg Messe GmbH,
said: “The acquisition of exhibitors is going
very well and we have already (editorial
note: in July) reached the level of applications
for the previous event. Many companies have
enlarged their stand spaces because Euroguss
offers them a major platform for cultivating
contacts and establishing new business relationships.
I expect around 400 exhibitors at
the exhibition in January. The number of international
exhibitors is also developing very
encouragingly, in some cases also from countries
that have not previously sent so many
firms, such as Turkey. Companies from Italy
and Sweden, each present with a pavilion, are
particularly strongly represented.
Regarding the product segments that will
be on show at Euroguss she continued: “The
product spectrum reflects the whole die casting
value chain: from technology and processes
through to products. The exhibitors are
die casting foundries, that is the manufacturers
of castings and components, and their
component suppliers, equipment suppliers
and service providers. They show die casting
technology, products for after-treatment of
castings, parting agents and operating materials
that are necessary in the manufacturing
process, quality control facilities, control systems,
drive technology and the broad field of
software.
Euroguss will be taking place for the tenth
time in 2014. What are the highlights at the
jubilee event? “We would like to celebrate
this anniversary with all exhibitors and visitors
and are organising a special show to mark the
occasion. This will examine the development
of die casting and span the period from the
past to the future. The show takes place in
the entrance area during the exhibition. The
occasion obviously calls for a real birthday
party and we are also planning a few more
anniversary specials. In addition, the popular
special show ‘Research for Knowledge’, the
International German Die Casting Congress
with interesting presentations by experts for
experts, and the presentation of awards for
both the International Aluminium and Zinc
Die Casting Competitions are naturally on the
programme again.
■
EMO Hannover
16.09.-21.09.13
Hall 11 Stand E48
... we have all the pieces.
www.rosler.com
Innovative solutions from the world‘s leader in surface finishing

TECHNOLOGIE
Gießtechnisch verbunden: Hybride CFK-
Aluminium-Fügeverbindung für den Leichtbau
Leichtbau gilt als Schlüsseltechnologie.
Wo immer es um geringes Gewicht geht
und Massen bewegt werden müssen,
sind sie gefragt: Leichtmetalle, aber auch
Faserverbundwerkstoffe. Eine Methode,
die besten Eigenschaften verschiedener
Werkstoffe miteinander zu verbinden,
ist die Hybridbauweise. Sinnvolle Kombinationen
unterschiedlicher Materialien
sind zum Beispiel CFK und Aluminium.
Derzeit erfolgt das Verbinden dieser
Komponenten über ein adhäsives oder
mechanisches Fügen. Mit Blick auf gewichtsoptimierte,
integrale Strukturen
mit verbesserten mechanischen Eigenschaften
sind jedoch neue Konstruktionsbzw.
Fügemöglichkeiten von Interesse.
Wissenschaftler am Fraunhofer-Institut
für Fertigungstechnik und Angewandte
Materialforschung haben neue Lösungsansätze
für verschiedene Verbindungsarten
im Druckguss entwickelt.
Für die unterschiedlichsten Branchen können
integrale Übergangsstrukturen zwischen Aluminium
und CFK gewünschte konstruktive
und fertigungstechnische Möglichkeiten bieten:
eine Reduzierung von Gewicht, Bauraum
und Fertigungsschritten. Einsatzgebiete sind
nicht nur in der Luftfahrtindustrie zu finden,
auch bei Windkraftanlagen und im allgemeinen
Maschinenbau steigt die Nachfrage nach
leichten Bauweisen. Im modernen Automobilbau
setzen Fahrzeughersteller bereits komplette
CFK-Karosserien in Serienfahrzeugen
ein. Der Fahrzeugrahmen, der als separates
Bauteil hergestellt wird, ist dabei aus Aluminium
gefertigt. Zur Montage beider Bauteile ist
wiederum eine Verbindungstechnik zwischen
dem Alurahmen und der CFK-Karosserie
erforderlich, die hier meist über eine
kombinierte Verbindung aus Nieten und
Kleben erzielt wird.
Wissenschaftler am Fraunhofer-
Institut für Fertigungstechnik und
Angewandte Materialforschung haben
neue Lösungsansätze für verschiedene
Verbindungsarten im Druckguss entwickelt.
Alle untersuchten Systeme verfolgen
dabei die gemeinsame Strategie einer
sogenannten Übergangsstruktur zwischen
den zu fügenden Materialien
Aluminium und CFK. Dieser Übergang
vom Metall zum Faserverbundwerkstoff
wird unter der Berücksichtigung von fasergerechtem
Design sowie – im Vergleich zu
konventionellen Verbindungstechniken – reduziertem
Bauraum und Gewicht entwickelt.
Das eingebrachte Verbindungselement führt
zu einer galvanischen Entkopplung zwischen
den Werkstoffen und verringert somit das
Korrosionsverhalten des Werkstoffverbundes
Aluminium-CFK. Besonderer Vorteil dieser
Übergangsstrukturen, die aus hitzebeständigen
Glasfasern oder Titan bestehen können, ist die
fertigungstechnisch einfache direkte Integration
in Aluminiumbauteile mithilfe des Aluminiumgusses,
der im Bereich der Gießereitechnologie
am Fraunhofer Ifam untersucht
und erarbeitet wird. Unterstützt werden diese
Arbeiten durch die Abteilung Plasmatechnik
Hybridverbindung zwischen einem Aluminium-Druckgussbauteil
und CFK
und Oberflächen am Fraunhofer Ifam. Hier
werden geeignete Oberflächenmodifikationen
der Übergangsstrukturen entwickelt, die die
mechanischen und korrosiven Eigenschaften
der Verbindungen verbessern.
Das Projekt „Bauweisen für CFK-Aluminium-Übergangsstrukturen
im Leichtbau“ wird
durch die Deutsche Forschungsgemeinschaft
(DFG) gefördert.
■
© Ifam
ACTech nimmt Stoßwellenanlage zur Entkernung komplexer Gussteile in Betrieb
Die ACTech GmbH, Entwickler und Hersteller
von Gussteilprototypen mit Hauptsitz in
Freiberg / Sachsen, hat eine neue Anlage mit
Stoßwellentechnik zur Entkernung von Gussteilen
in Betrieb genommen. Mit der flexibel
einsetzbaren Technologie kann die Produktionszeit
von Gussteilen mit anspruchsvoller
Innengeometrie deutlich verkürzt werden.
ACTech ist nun bestens gerüstet für die Fertigung
von Bauteilen mit zunehmend komplexer
werdender Kerngeometrie, zum Beispiel
von Hochleistungs-Zylinderköpfen. Derartige
Teile waren bislang nur mit extremem Aufwand
realisierbar.
Dank der neuen Technologie muss das
Bauteil nicht mehr mehrere Tage in den Glühofen,
wenige Minuten im Wasserbad genügen.
Die Stoßwellentechnologie ersetzt neben thermischen
auch mechanische Entkernverfahren
wie das Entkernungsstrahlen und das damit
verbundene Risiko einer Beschädigung des
Bauteils. Außerdem reduziert die neue Anlage
die notwendigen Endoskopien zur Kontrolle
des Reinigungsfortschritts. Nach Abschluss
eines viermonatigen Testlaufs mit
mehr als 200 entkernten Teilen ist die Stoßwellenanlage
bei ACTech nun im Regelbetrieb
im Einsatz. Vor allem Kunden aus der Automobilbranche
profitieren von den verkürzten
Produktionszeiten. ACTech kann Gussteilprototypen
nun noch schneller und kostengünstiger
ohne Qualitätseinbußen herstellen.
Bei der Stoßwellen-Entkernung wird das
Bauteil in einem Wasserbad vor zwei Elektroden
positioniert. Über die Elektroden werden
hoch aufgeladene Kondensatoren schlagartig
entladen. Das löst eine hochenergetische,
hochfrequente Schockwelle aus, die das Gussteil
durchläuft, vorhandene Kernreste zerstört
und die Verschmutzungen ins Wasser
spült. Neben der Entfernung von Gusskernresten
lässt sich die Stoßwellenanlage auch
zur Beseitigung von keramischen Kernresten
bei Feingussverfahren und von festsitzenden
Spänen nach der mechanischen Bearbeitung
einsetzen.
Die positive Kosten-/Nutzen-Rechnung
sowie die Flexibilität der Stoßwellentechnologie
und die guten Ergebnisse vorangegangener
Tests führten dazu, dass ACTech bereits ein
Jahr nach den ersten externen Tests eine eigene
Stoßwellenanlage in Freiberg in den Regelbetrieb
nimmt.
■
72 ALUMINIUM · 9/2013

TECHNOLOGY
© Behringer
Automated band saws for precise linear cuts
Four modern band saw systems from
Behringer GmbH separate parts for largescale
industrial and private constructions,
subway and aircraft construction and the
machine construction and energy sectors
for an Asian customer of Behringer
GmbH.
Integrated in an existing roller conveyor system, the HBP800-1201 aluminium
bandsaw from Behringer ensures fast, high-precision cutting of the lightweight
material
With an annual volume of 500,000 tonnes,
the company is one of the major processors
for aluminium. Window and door profiles
are mainly manufactured for the private
and industrial sectors as well as components
for ships, aircraft and for the energy sector.
Processing is usually with profiles and tubes
but also solid materials with highly diverse
cross-sections and diameters. In the past years
Behringer from Kirchardt in Germany has
supplied a total of four partly automated band
saws that with their highly precise linear cuts
ensure ready-to-mount sections that are postprocessing
redundant.
First pressed, then sawn
Two of the saw systems are each connected
to large aluminium presses for bringing the
profiles into form prior to sawing. “The
HBP800-1201 and HBP410-923N straight cut
aluminium band saws are not isolated solutions
but were integrated into an existing periphery
consisting of diverse roller conveyors
and cross conveyor systems,” explains Achim
Müller, head of Sales at Behringer. They take
the place of two large circular saws that were
previously integrated in the peripheral setup
and ensure problem-free processing, characterised
by convenient tool changing and highly
reliable operation. Following the separation
process the profiles are transported onwards
via the roller conveyors either to the packing
location for dispatch or into an intermediate
storage area for subsequent processing.
A second HBP800-1201 of aluminium with
a cutting range of
up to 1,200 mm
in height and 800
mm in width operates
independently
without connection
to other systems.
This is equipped
with a 25 metrelong
feed and discharge
roller conveyor,
and loading
of the machine is
via a hall crane
from a blank piece
storage area. Following
the separation
process the
crane takes up the
cross-cut profiles
and deposits them
for subsequent dispatch.
Both large band saws feature a saw band
inclined by four degrees for efficient cutting
of grouped, square hollow sections. Controlled
by computer, the feed function and cutting
speed of the saw band are adapted automatically
to the input material width. A cut monitoring
system controls cutting progression of
the material to be cut. Dynamic sawing and retracting
achieves increased band service life as
well as optimal cut edges. The ejection height
of the chip container is 1,200 mm due to the
large volume of chips produced
during aluminium sawing.
Both HBP800-1201 aluminium
saw systems also feature
a hydraulic vertical tensioning
device with a wide thrust piece
installed to the machine. The
horizontal tensioning device
and this supplementary vertical
tensioning device enable several
tubes in a single position
or package to be cut up to the
height of the fastening clamps.
All fastening clamps have a
smooth, hardened surface for
avoidance of imprints into the
material. The movable fastening
clamp features plastic plates to achieve
effective clamping of packages, for example
with rectangular tubes.
High efficiency and maximum precision
The HBM540ALU automatic band saw ensures
high performance machining with enormous
precision. “The cutting performance is
many times higher than with conventional
band saws,” testifies Mr Müller. A servo drive
and ball screw enable point-precise, rapid infeed
to the band saw as well as a highly constant
and precisely adjustable saw feed rate.
Constant cutting feed rate or constant cutting
force can be optionally specified, and this ensures
an optimal service life of the tool and
optimal separation results as well.
Sawing and retracting is also dynamic with
the HMB540ALU. As with the HBP800-1201
large band saws, the benefits are optimal cut
edges with the separation of tubes and profiles
as well as protection of the band. The high efficiency
band saw has an extended supply axis
and the stroke length of the feed gripper is
1,440 mm. With this version the feed gripper
is configured permanently for linear directions
and the fixed jaw automatically moves away
from the stop edge during the return stroke.
A hydraulic vertical tensioning device enables
economic sawing of packages and layers. A
cutting channel extension means the saw band
can be freely retracted following the separation
process.
With this investment in the new saw machines
the company has not only planned for
the moment. “A further expansion of production
capacity is expected, and the currently
existing machine park readily permits such an
increase,” summarises Mr Müller. ■
Aluminium profiles with different diameters are cut with maximum
speed and precision on Behringer bandsaws
ALUMINIUM · 9/2013 73

TECHNOLOGIE
Innovative Lösungen für das Strahlen von Gussprodukten
Die Strahltechnik zählt in der Gießereibranche
zu den unverzichtbaren Verfahren,
um erforderliche Oberflächenbeziehungsweise
Produkteigenschaften
herzustellen. Dabei ermöglichen neue
Entwicklungen für das automatisierte
Strahlen eine deutlich wirtschaftlichere
sowie qualitativ hochwertigere Bearbeitung
von Gussprodukten und erweitern
das Einsatzspektrum.
Geht es zum Beispiel um die Bearbeitung und
das Oberflächenfinish von Gussteilen für die
Automobilindustrie, sind die Anforderungen
an Qualität, Wirtschaftlichkeit und Durchsatz
extrem hoch. Dies waren auch die Vorgaben
eines süddeutschen Automobilherstellers bei
der Auswahl eines Strahlsystems für das Restentsanden
und Oberflächenfinish von Zylinderköpfen
an verschiedene Strahlanlagenhersteller.
Gefertigt werden die 510 x 320 x 150
mm (L x B x H) großen und 18,8 kg schweren
Werkstücke im Schwerkraft-Kokillenguss.
Die Rösler Oberflächentechnik GmbH entwickelte
ein entsprechend den Kundenanforderungen
ausgelegtes Anlagenkonzept auf
Basis des Roboblasters – einer für unterschiedliche
strahltechnische Bearbeitungsverfahren
vom Entgraten, Entsanden bis zum Verdichtungsstrahlen
(Kugelstrahlen) einsetzbaren
Kombination aus Strahlanlage und Sechsachsroboter.
Mitentscheidend beim Zuschlag
für dieses System RROB 800/750-4 waren
auch die guten Erfahrungen des Autobauers
mit einem bereits eingesetzten Roboblaster-
Strahlsystem aus Untermerzbach und die
Einhaltung der vorgegebenen Werkstückdurchsatzmenge.
Strahlen im 16-Sekundentakt
Bei dieser Lösung beschickt ein Roboter
abwechselnd zwei Strahlanlagen.
Dies ermöglicht die geforderte redundante
Auslegung des Strahlprozesses
und verhindert, dass es beim Ausfall
einer Anlage zum Produktionsstillstand
kommt. Die vorgegebene, enge
Taktzeit von nur 16 Sekunden pro
Werkstück realisierte der Anlagenbauer
mit einem Doppelgreifer, durch den
der Roboter jeweils zwei Werkstücke
gleichzeitig aufnehmen kann.
Die Zuführung der Zylinderköpfe
zur Roboterzelle erfolgt über eine
Rollenbahn mit Seitentransfereinheit.
Dort werden diese von einem
© Rösler
Innovative shot blasting solutions for foundries
In the foundry industry shot blasting is
a key surface treatment technology for
producing the required surface finishes.
Recent developments in the automation
of shot blast processes have contributed
towards significant improvements in the
cost effectiveness and quality of the surface
preparation function, at the same
time they have expanded the range of applications
for this technology.
Das Bearbeitungsspektrum dieser Hochleistungsstrahlanlage mit Einarmroboter
reicht vom Entgraten über Oberflächenfinish bis zum Shotpeening schlagempfindlicher
Werkstücke unterschiedlicher Dimensionen. / The operating scope of this
high performance blasting system ‘Roboblaster’ with one arm robot comprises deburring,
surface finishing as well as shot peening of impact sensitive components
of various dimensions.
For example, when it comes to the quality of
the surface finish and cost efficiency of high
volume production castings for the automotive
industry, the technical and cost requirements
are extremely challenging. This was also
the case with the specifications for a shot blast
system for the removal of residual core sand
and general blast cleaning of cylinder heads
which a car manufacturer in Southern Germany
presented to various shot blast equipment
suppliers. The products with dimensions
of 510 x 320 x 150 mm (L x W x H) and a
weight of 18.8 are produced by gravity die
casting technology.
In compliance with the customer specifications
the German company Rösler developed
a blast system concept on the basis of the
innovative Roboblaster; the combination
of a shot blast machine with a 6-axis
robot that can be used for a variety
of applications: from bur and sand removal
all the way up to shot peening. Key factors in
the customer’s decision for the Rösler RROB
800/750-4 were the excellent performance of
a similar Roboblaster shot blast system from
Rösler running at one of the car manufacturer’s
facilities and the supplier’s compliance
with the capacity requirements.
A 16 second shot blast cycle time
The Rösler shot blast system consists of two
machines and one robot alternately loading
parts into the two blast machines. This concept
complies with the ‘redundancy’ requirement,
that is in case one shot blast machine becomes
in-operational, the manufacturing process
does not have to be stopped. The specified
cycle time limit of only 16 seconds was met
with a dual gripper allowing the robot to pick
up two parts at the same time.
The cylinder heads are transported to the
robotic shot blast cell with a roller conveyor
equipped with a cross transfer unit. There the
parts are precisely positioned for pick up by
the robot gripper. In the blast chamber the
duplex gripper places the cylinder heads on
parts-specific work piece fixtures
and, subsequently, moves out
of the blast chamber. After the
blast chamber door has been
closed, the hinged turbine
flaps open to initiate the flow
of blast media, whilst at the
same time the work piece
fixtures with the mounted
cylinder heads start rotating.
This rotational movement
ensures a homogeneous
and complete coverage
of the part surface without
any ‘shadow’ effect.
The blast media consists of
stainless steel shot with sizes
of 0.5 to 0.8 mm. After the
blast cycle the turbine flaps
are closed to stop the media
flow. The work piece fixtures
continue rotating until the
chamber door is completely
open. This allows the initial
removal of residual blast
media and core sand from
the parts while they are still
74 ALUMINIUM · 9/2013

TECHNOLOGY
in the blast chamber.
Each blast machine is equipped with four
high performance turbines, type Hurricane
H42, with a diameter of 420 mm and an installed
drive power of 15 kW each. The optimum
placement of the turbines with their required
tilt angle was determined by the Rösler
engineers using a 3D simulation of the shot
blast process.
To minimise the equipment wear caused by
the high blast intensity, the blast chamber and
work piece fixtures are made from extremely
wear resistant manganese steel. In addition,
the inside of the blast chamber is lined with
easy to replace overlapping 12 mm thick manganese
steel plates.
The challenging task of
removing residual blast media
The stringent customer requirements did not
only apply to cycle time and precision of the
automated process but also extended to the
allowable residual blast media/core sand in the
cylinder heads. The specification of only 0.5
grams per part required a highly sophisticated
solution: After the shot blast process the robot
transfers the cylinder heads in pairs of two into
a blast media removal system comparable to a
Ferris wheel. The parts are moving in a precise
orbit while at the same time being rotated in
different, pre-defined directions. In addition, a
vibratory motor mounted to the wheel frame
induces vibrations in the cylinder heads which
help shake out blast media from the difficult to
reach areas in the water channels.
The small sand quantity in the blast media
(only residual core sand) did not require a
magnetic separator. It was possible to handle
the media classification with a more economical
dual stage air wash separator. This cleaning
system ensures full compliance with the specified
residual contamination in the blast media
of less than 0.1 % of the media volume and
media loss of less than 1% during the media
classification process.
When it comes to space requirements, the
Roboblaster could also fully meet the customer’s
expectations, including an all-around noise
protection cabin the complete system could be
placed in an area of only 10.4 x 8.6 m. To allow
maintenance work on the shot blast machines
during the 3-shift operation, the work area of
the robot is enclosed with a safety fence. The
complete shot blast system was installed on
the first floor of the customer’s foundry. The
system components were broken down so that
they could easily be transported in the on-site
heavy duty elevator with dimensions of 6 x
4 x 3 m.
■
Ausrichtsystem positionsgenau auf die Übernahme
durch den Robotergreifer vorbereitet.
In der Strahlanlage positioniert der Duplexgreifer
die Zylinderköpfe an teilespezifisch
gestalteten Werkstückaufnahmen und fährt
wieder aus der Strahlkammer. Nach dem
Schließen der Kammertür geben die Turbinen-
Schotts den Strahlmittelzufluss frei, gleichzeitig
werden die Gussteile über die Werkstückaufnahmen
in Rotation versetzt. Diese kontinuierliche
Lageveränderung gewährleistet,
dass die Zylinderköpfe allseitig gleichmäßig,
ohne Schatteneffekte gestrahlt werden.
Als Strahlmittel kommt Edelstahl in einer
Korngröße von 0,5 bis 0,8 mm zum Einsatz.
Nach der vorgegebenen Strahlzeit verschließen
die Schotts wieder die Turbinen, während
sich die Werkstückaufnahmen bis zum vollständigen
Öffnen der Strahlkammer weiter
drehen. Dies bewirkt, dass die Werkstücke
bereits im Strahlraum vorentleert werden.
Ausgestattet ist jede Strahlanlage mit insgesamt
vier Hochleistungsturbinen vom Typ
Hurricane H42 mit 420 mm Durchmesser und
einer Antriebsleistung von jeweils 15 kW. Die
optimale Platzierung und erforderlichen Neigungswinkel
der Turbinen ermittelte Rösler
in der Konstruktionsphase durch 3D-Simulation
des Strahlprozesses.
Um der starken Beanspruchung durch die
hohe Strahlintensität vorzubeugen, sind die
Anlagengehäuse und Werkstückaufnahmen
aus extrem verschleißfestem Manganstahl
ausgeführt. Zusätzlich sind die Arbeitskammern
mit 12 mm starken, spaltfrei verlegten
Manganstahlplatten ausgekleidet.
Herausforderung Strahlmittelentleerung
Hohe Anforderungen galt es aber nicht nur
hinsichtlich Taktzeit und Präzision zu erfüllen,
sondern auch beim Restsand-/Strahlmittelgehalt.
Die Vorgabe
von lediglich 0,5
Gramm pro Werkstück
machte hier
ebenfalls eine sehr
ausgeklügelte
Lösung erforderlich:
Nach dem
Strahlen übergibt
der Roboter die
Zylinderköpfe
paarweise in eine
vergleichbar mit
einem Rhönrad
gestaltete Entleereinheit.
Die Werkstücke
bewegen
sich in einer exakt
festgelegten Bahn, wobei sie in definierte
Richtungen gedreht werden. Hierbei werden
über einen Unwuchtmotor am Drehgestell
Anzeige
Vibrationen in das Werkstück geleitet, durch
welche das Strahlmittel auch aus schwer zugänglichen
Stellen des Wasserraumes gerüttelt
wird.
Der eher geringe Restsandgehalt machte es
bei dieser Anlage möglich, auf einen Magnetseperator
zu verzichten und die Strahlmittelaufbereitung
über eine kostengünstigere
Doppelkaskadenwindsichtung zu lösen. Sie
gewährleistet, dass sowohl der geforderte
Restschmutzwert kleiner 0,1 Vol.% im Strahlmittelfluss
als auch die Vorgabe hinsichtlich
des Strahlmittelaustrags bei der Aufbereitung
von kleiner 1% eingehalten werden.
Das Roboblaster-Strahlsystem auch hinsichtlich
des erforderlichen Platzbedarfs sehr
wirtschaftlich: Es wurde auf einer Fläche von
nur 10,40 x 8,60 Metern untergebracht und
ist komplett in eine Schalldämmkabine eingehaust.
Um die Strahlanlagen während des
Dreischichtbetriebs warten zu können, ist der
Arbeitsbereich des Roboters zusätzlich mit
einem Schutzgitter abgegrenzt. Aufgestellt
wurde das Gesamtkonzept im ersten Stock der
Gießerei des Autobauers und war dabei auch
so flexibel, dass es im Lastenfahrstuhl (6 m x 4
m x 3 m) transportiert werden konnte. ■
Engineering,
construction and
revamping of melting
and holding furnaces for
the non-ferro industry
ALUMINIUM · 9/2013 75

ANWE NDUNG
Aluminiumtube feiert 100 Jahre Erfolgsgeschichte
Vor 100 Jahren wurden die technischen
Voraussetzungen für die einzigartige
Erfolgsstory der Aluminiumtube geschaffen:
1913 entwickelte und konstruierte
der damals 28-jährige Alfons Mall in
Baden (Deutschland) ein Maschinenprogramm
eigens für die Massenproduktion
von Tuben. Nahezu zeitgleich fanden
in der Schweiz und bald darauf auch in
Deutschland erste Versuche statt, Tuben
aus Aluminium herzustellen.
Der erste Weltkrieg stoppte zunächst den
weiteren Markterfolg der Aluminiumtube,
doch war der Grundstein für den Aufbau der
modernen Tubenindustrie gelegt. Die Entwicklung
der massenhaften Produktion der
Aluminiumtube erfolgte schließlich in den
1920er und besonders in den 1930er Jahren
in Deutschland. Bis dahin dienten zur Herstellung
der Metalltuben ausschließlich Zinn, Blei
und verzinntes Blei. Zinn war jedoch sehr teuer,
kostete Devisen und unterlag ebenso wie
Blei zeitweise der Zwangsbewirtschaftung. Die
Verwendung von Blei für Tuben war zudem
durch das Lebensmittelgesetz beschränkt. So
übertraf bereits 1939 die Produktionsmenge
der Alutuben diejenigen aus Weichmetall.
Der Siegeszug der Aluminiumtube hatte
begonnen und setzte sich auch nach dem zweiten
Weltkrieg fort. Auch heute noch stehen
die Tuben aus Aluminium mit ihren Produktionszahlen
an der Spitze aller hergestellten
Tuben. Die Mitgliedsfirmen der etma (european
tube manufacturers association), die für
über 80 Prozent der gesamten europäischen
Tubenproduktion stehen, meldeten für 2012
ein Rekordergebnis von über zehn Milliarden
produzierten Tuben. Davon waren knapp
über 40 Prozent aus Aluminium, mit jeweils
circa 30 Prozent am Gesamtvolumen teilen
sich Kunststofftuben und Tuben aus Laminat
die restliche Produktionsmenge.
Genau 100 Jahre nach den ersten Anfängen
hat die Alutube offensichtlich nichts an
ihrer Attraktivität eingebüßt. Ganz im Gegenteil:
Der rasante Fortschritt in der Druck- und
Veredelungstechnologie macht sie heute optisch
so interessant und vielseitig wie nie zuvor.
Dazu kommen ihre bekannten Vorteile
wie das leichte Gewicht, die einfache Handhabung,
ihre exzellenten Hygienestandards, die
hervorragenden Barriereeigenschaften und
ihr optimaler Produktschutz, um nur einige
der wichtigsten Aspekte zu nennen.
Aluminiumtuben werden daher heute vor
allem im Lebensmittelbereich, in der Pharmazie
und in der Kosmetikindustrie eingesetzt.
Und die ausgezeichnete Recyclingfähigkeit
der Alutube macht sie auch 100 Jahre nach
ihrer Erfindung gerade in der heutigen Zeit,
in der Ressourceneffizienz und Nachhaltigkeit
ganz oben auf der Agenda stehen, besonders
aktuell.
■
Aluminium tube celebrates centenary
Eine Erfolgsgeschichte – die Aluminiumtube
Exactly one hundred years ago a new
technical development made the industrial-scale
production of aluminium tubes
feasible, and marked the start of a unique
success story. In 1913 Alfons Mall, who
was 28 years old and living in Baden in
Germany at the time, developed and constructed
a range of machines for the mass
production of tubes. In the same year,
tests were carried out to manufacture
tubes from aluminium, first in Switzerland
and then in Germany.
The First World War then put a temporary
stop to any further market success of the aluminium
tube. However, the foundation stone
for the modern tube industry had been laid.
The large-scale production of aluminium tubes
took place in Germany after the war, in the
1920s and particularly in the 1930s. Metal
tubes had previously only been made from
tin, lead or tin-plated lead. However, tin was
very expensive and required foreign currency;
and just like lead, it was subject to controls
for a time. Further, food legislation limited the
use of lead for tubes. By 1939, more tubes
were produced from aluminium than from the
soft metal.
The triumphant advance of the aluminium
tube had begun, and it continued unabated
The aluminium tube – a success story
after the Second World War. Production figures
for the aluminium tube still top the list
of tubes produced even today. The member
companies of etma, the European tube manufacturers
association that represents over 80%
of all tube production in Europe, reported a
record result in 2012, with over ten billion
tubes produced. Of these, slightly more than
40% were alu tubes, with plastic and laminate
tubes accounting for the remaining production,
each with a share of roughly 30% of
total volume.
As it celebrates its centenary, the aluminium
tube has lost none of its attractiveness.
On the contrary: rapid developments in printing
and conversion technology have made it
visually more interesting and versatile today
than it has ever been. On top of this there
are the well-known benefits like light weight,
easy handling, its excellent standards of hygiene,
outstanding barrier properties and optimal
product protection.
Alu tubes are now used primarily in the
food and pharmaceutical sectors and in the
cosmetics industry. And particularly in today’s
world, where resource efficiency and sustainability
are right at the top of the agenda, the aluminium
tube’s excellent recyclability means it
is still a highly modern form of packaging that
is very much in keeping with the times. ■
© etma
76 ALUMINIUM · 9/2013

APPLICA TION
Opel stellt neuen Vollalu-Dreizylinder auf IAA vor
Der deutsche Automobilhersteller Opel
wird auf der Internationalen Automobilausstellung
(IAA) in Frankfurt im September
seinen neu konstruierten Vollaluminium-Dreizylinder
vorstellen. Der
direkteinspritzende Turbobenziner mit
einem Liter Hubraum sei nicht nur umweltfreundlich,
sondern zeichne sich auch
durch eine vorbildliche Laufkultur aus,
betont Opel.
Das 85 kW / 115 PS starke Aggregat liefert ein
beachtliches Drehmoment von 166 Nm über
von Verbrauch und Emissionen. Wir wollten
zeigen, dass ein Dreizylinder mindestens
ebenso viel Laufkultur an den Tag legen kann
wie Triebwerke mit vier und mehr Zylindern“,
erklärte Opel-Ingenieur Matthias Alt.
Der Motorblock aus Aluminium-Druckguss
ist nicht nur leicht, seine Konstruktion dämmt
auch die Abstrahlung strukturbedingter Triebwerksgeräusche
ein. Die Hochdruck-Einspritzanlage
ist vom Zylinderkopf isoliert, um
die Übertragung von Schwingungen zu vermeiden.
Die Integration des Auspuffkrümmers in den
Alu-Zylinderkopf ist ein Beispiel für Präzisionsarbeit:
Der Krümmer ist unmittelbar
mit dem agilen, wassergekühlten Turbolader
verschraubt. Diese kompakte Konfiguration
fördert das spontane Ansprechverhalten des
Laders bereits bei niedrigen Drehzahlen.
Das maximale Drehmoment von 166 Nm
liegt ab 1.800 U/min an. Damit hat der neue
Dreizylinder bei gleicher Drehzahl 30 Prozent
mehr Durchzugskraft zu bieten als der
1,6-Liter-Motor.
■
Opel presents new all-aluminium 3-cylinder at IAA
© GM Company
Der neue 1-Liter-Dreizylinder von Opel
Opel’s all-new 1.0-liter direct injection engine
ein breites Drehzahlband von 1.800 bis 4.700
U/min hinweg. Damit generiert der 1,0-Liter-
Turbo mehr Durchzugskraft als viele größere
Triebwerke in der gleichen Leistungsklasse.
Gleichzeitig sei der neue Motor ein Fünftel
sparsamer als der aktuelle 1,6-Liter-Saugbenziner
von Opel mit gleicher Leistung.
Sein Debüt feiert der Dreizylinder zusammen
mit einem ebenfalls neu entwickelten,
manuellen Sechsgang-Getriebe in Leichtbauweise
nächstes Jahr im Opel Adam. Mit 37
Kilogramm Trockengewicht ist es rund 30
Prozent leichter als die aktuelle Ausführung.
Der 1.0 SIDI (Spark Ignition Direct Injection),
mit zwölf Ventilen ist das erste Mitglied
einer neuen, modular aufgebauten Motorenfamilie
von Drei- und Vierzylinder-Benzinern
im Hubraumspektrum bis 1,6 Liter. Schlüsselmerkmale
dieser Familie sind modernste
Technologien wie SIDI, variable Ventilsteuerung
und der Leichtbau-Motorblock aus Aluminium.
„Bei der Entwicklung dieses Motors
erreichten wir weit mehr als die Reduzierung
The German car manufacturer Opel will
be celebrating a new all-aluminium threecylinder
at the Frankfurt International
Motor Show (IAA) in September. The
1.0-litre turbo gasoline engine is not only
climate-friendly, it also represents a new
benchmark for refinement in three-cylinder
engines, says Opel.
Developing 85 kW / 115 hp, this pocket powerhouse
also delivers high low-end torque of
166 Nm all the way from 1,800 to 4,700 rpm.
The 1.0 SIDI Turbo (Spark Ignition Direct
Injection) generates more torque throughout
its operating range than equally powerful,
higher displacement engines, while fuel efficiency
is improved by 20% compared to
Opel’s current 1.6-liter naturally aspirated
power unit.
To be launched in the ‘Adam’ small car
next year with an all-new six-speed gearbox,
the 12-valve, 1.0 turbo is the first
in a new, modular family of three
and four-cylinder gasoline engines
in the up to 1.6 litres class. Stateof-the-art
technologies such as
direct injection, continuously variable
valve timing, and a lightweight
aluminium cylinder-block, are key
efficiency enablers.
“In developing this small engine,
we not only set out to minimise
fuel consumption and CO 2
emissions, we also wanted to demonstrate
that three cylinders can
be just as refined as four or more,”
says Opel engineer Matthias Alt.
The cylinder block made of
high pressure die-cast aluminium
is designed to reduce radiated
and structure-borne engine noise,
as well as reduce weight. The high-pressure
fuel rail and injectors are also structurally isolated
from the cylinder head to minimise the
transmission of pulsing, while the fuel pump
and fuel line are acoustically treated.
The integration of the exhaust manifold
inside the aluminium cylinder head is another
example of precision engineering. The exhaust
manifold is bolted directly to the lowinertia,
water-cooled turbocharger. This compact
installation contributes to the delivery of
a fast boost charge for strong, low-end power.
Maximum torque of 166 Nm from just 1,800
rpm is almost 30% higher than the 1.6-litre
engine generates at the same rpm.
The 1.0 SIDI Turbo is mated to an all-new,
six-speed manual gearbox specially designed
for medium torque applications. With a dry
weight of only 37 kilograms, it is about 30%
lighter than its current counterpart. ■
Der 1.0 SIDI Turbo ist an ein neu konstruiertes Sechsgang-
Schaltgetriebe gekoppelt
The 1.0 SIDI Turbo is mated to an all-new, six-speed manual
gearbox
ALUMINIUM · 9/2013 77

COMPANY NEWS WOR LDWIDE
Aluminium smelting industry
© Dubal
Alcoa starts modernising Massena plant
Alcoa has officially broken ground on work
to upgrade its operations in Massena, New
York, including the planned construction of a
new potline at its Massena East facility. The
project is supported by a USD10m loan from
the North Country Economic Development
Loan Fund, and a power agreement with the
New York Power Authority (NYPA).
New York has committed to supply 478
MW of low-cost electricity to Alcoa’s Massena
complex, a step that led the company to move
forward with its modernisation plans and allowed
it to retain 1,000 jobs at the facility.
NYPA, the largest state power organisation in
the USA, and Alcoa have agreed to a hydropower
contract until 2045, with an option for
Alcoa to extend the agreement until 2055.
Under the terms of the contract, agreed to
in 2009, Alcoa committed to making capital
investments of at least USD600m, of which
USD42m is represented by the potline expansion.
Alcoa to further cut smelting capacity
Alcoa will close or curtail 164,000 tonnes of
aluminium smelting capacity in the US and
Brazil as part of its review announced in May.
One potline representing 40,000 tonnes at
the Massena East plant in New York will be
permanently closed. In addition, the company
has started to temporarily curtail 124,000
tonnes at its smelters in Brazil. The measures
will be complete by the end of September.
Bob Wilt, president of Alcoa’s Global Primary
Products, commented: “Aluminium
prices, including premiums, have fallen to
four-year lows and we continue to operate in
an uncertain, volatile market.” To date, Alcoa
has announced closures or curtailments
representing 269,000 tonnes of the 460,000
tonnes placed under review in May. This includes
the permanent closure of 105,000
tonnes of capacity announced earlier at Alcoa’s
Baie-Comeau smelter in Canada. In addition,
the company is to close its Fusina smelter in
Italy representing 44,000 tonnes that was not
part of the May review.
Once the Massena and Brazil closures and
curtailments are complete, Alcoa will have
646,800 tonnes or 16% of smelting capacity
idle. Alcoa’s review of its primary metals
operations is consistent with the company’s
2015 goal of lowering its position on the world
aluminium production cost curve by ten percentage
points and the alumina cost curve by
seven percentage points.
Alcoa to close Fusina aluminium smelter
Alcoa is to permanently close its Fusina primary
aluminium smelter in Venice, Italy, removing
a further 44,000 tpy from its 4.2m tpy
global smelting system. The plant has been
curtailed since June 2010. The Fusina rolling
mill operates separately from the smelter and
is not affected by the closure. Total restructuring-related
charges are expected to be between
USD30-35m after-tax of which about
50% is non-cash. In November 2012, Alcoa
curtailed its Portovesme smelter in Italy too.
NZAS signs new electricity
agreement for Tiwai Point smelter
The future of New Zealand’s Tiwai Point aluminium
smelter has been secured through
the signing of a long-term electricity agreement.
New Zealand Aluminium Smelters
Ltd (NZAS), the company that operates the
smelter, signed the deal with Meridian Energy
Ltd after 12 months of negotiations. The previous
contract, which came into effect from
1 January 2013, had included price increases
which threatened the future of the smelter
in the face of falling aluminium prices and
the strong New Zealand dollar. The revised
contract sets new reduced pricing from 1
July 2013, though details were not disclosed.
Separately, the NZ Government has provided
a USD30m payment to NZAS on finalisation
of contractual negotiations to secure the medium
term future of the smelter, one of New
Zealand’s largest industrial facilities.
Rio Tinto Alcan curtails
aluminium production in Quebec
Rio Tinto Alcan will immediately curtail
50,000 tonnes of production at its Shawinigan
smelter in Quebec and will progressively curtail
the remaining 50,000 tonnes of capacity
by the end of November 2013. The company
refers to dated smelter technology and continued
weakness in aluminium prices. Located
in Quebec, Canada, the Shawinigan smelter
was commissioned in 1942 and employs 425
people. Rio Tinto Alcan will provide any employees
impacted as a result of the curtailment
of production with re-training and job-search
assistance through the company’s employee
assistance programme and through collaboration
with regional and provincial partners.
Ormet curtails half its operations
At the end of July, the Public Utilities Commission
of Ohio denied the timing of Ormet’s
request for relief from the current power rate
with Ohio Power and affirmed the matter
has been set for formal hearing at the end of
August. Ormet was forced to file for bankruptcy
in February due to low metal prices
and exceedingly high power costs. The Ohio
Power industrial rate which establishes the
base rate for Ormet to procure power has
increased from USD39.66/MWh when the
Unique Arrangement was established in 2009
to USD62.83/MWh in June 2013, which is an
increase of some 58%. The Unique Arrangement
was created as an incentive to maintain
and create jobs, which Ormet has successfully
78 ALUMINIUM · 9/2013

COMPANY NEWS WOR LDWIDE
done to date. In 2013 these rate increases will
virtually eliminate the benefits provided by
the Unique Arrangement.
The consequence of this decision is Ormet
must immediately begin the shutdown of half
of its existing operations to conserve cash.
This means three out of six potlines or a capacity
of 135,000 tpy will be shut down.
Aluminij Mostar secures
power contract until year-end
2012, up 1.8% from the year before.
Vendanta restarts alumina refinery
Vedanta Aluminium Ltd has restarted its alumina
refinery at Lanjigarh in Odisha, about
seven months after the company had shut
down the plant due to shortage of bauxite.
The company has revived its plant by procuring
bauxite from Jharkhand, Chhattisgarh
and Gujarat. The refinery has a nameplate capacity
of 1m tpy, but will initially run at 60%
of its capacity.
■
Secondary smelting and recycling
Bosnia’s primary aluminium smelter Aluminij
Mostar has secured a power contract with
Slovenian GEN-I on the supply of 100 MW for
a 5-month period as from 1 August. The power
contract offers better conditions than the
previous one with Croatian HEP, especially
when transmission costs are taken into account,
says CEO Ivo Bradvica. The new price
scheme, however, was not disclosed. Aluminij’s
need of electricity amounts to 225 MW.
The remaining 125 MW will be supplied by
Elektroprivreda HZ Herceg-Bosna. The smelter
was under threat of closure due to high
electricity prices paid previously.
EU Commission approves
merger of Emal and Dubal
The European Commission has approved the
merger of Dubal and Emal into the newly
created joint venture Emirates Global Aluminium.
The deal would not raise competition
concerns in the EU because of the very
limited overlap between the parties’ activities
and the presence of other competitors, which
are not capacity constrained.
■
Bauxite and
alumina activities
Vale mulls divesting stake in
Brazilian bauxite producer MRN
Miner Vale is considering selling its stake in
Brazilian bauxite producer Mineração Rio
do Norte (MRN). Vale SA is currently MRN’s
main stakeholder with 40% shares, followed
by BHP Billiton (14.8%), Rio Tinto Alcan
(12%) and other stakeholders. Vale’s strategy
is to have a smaller portfolio, focused on its
more profitable divisions. Iron ore remains
Vale’s main business along with coal.
MRN produced 17.1m tonnes of bauxite in
© Hydro
Alumetal doubles capacity at
secondary aluminium plant
Foundry alloy producer Alumetal has doubled
the capacity of its Nowa Sol facility in western
Poland to 66,000 tpy with the launch of a second
production line. Alumetal operates three
production sites in Poland with a total capacity
of 170,000 tpy of aluminium alloy, following
the latest expansion at Nowa Sol. The company
expects to produce 120,000 tonnes of
aluminium alloy in 2013 as the new production
line is ramped up to full capacity. Its two
other facilities are in Gorzyce, in south-east
Poland, and Kety, in southern Poland.
MRT invests in new
automated die casting cell
UK-based company MRT Castings has commissioned
a new advanced die casting cell
that further enhances the high quality of its
die casting facilities. The Colosio PFO 250 die
casting cell’s innovative features include:
• Real-time shot control: by monitoring and
storing process data, the advanced control
system of the new machine affords MRT accurate
repetition of all the injection parameters,
pressures, speeds and strokes to ensure consistent
high quality casting at all times.
• Fully integrated two-axis automatic die
sprayer – enabling fast, effective and consistent
lubrication of even the most complex die
forms.
• Robotic casting extractor with integrated
cooling conveyor – increasing productivity
and improving repeatability.
• A new Ramsell-Naber gas-fired melting
furnace with recuperative burner technology,
thus reducing energy consumption and emissions.
The Colosio PFO 250 delivers a locking
force of 250 tonnes, making it suitable for
aluminium components up to 3.5 kg.
Alupro: That calls for a Carlsberg!
The UK Aluminium Packaging Recycling
Organisation (Alupro) has announced that
Carlsberg UK has become its newest member
and has also joined the funding partners of
the ‘Every Can Counts’ recycling programme.
Carlsberg UK is the first brewer to join Alupro
and its membership marks the company’s
commitment to increase the recovery and recycling
of its aluminium cans used across its
portfolio of beer and cider brands.
Through its funding partnership of the
Every Can Counts programme, Carlsberg aims
to take the ‘away from home’ recycling message
directly to consumers, in particular at outdoor
events such as music festivals. Already
this summer Carlsberg UK staff have been
supporting recycling promotions under the
ALUMINIUM · 9/2013 79

COMPANY NEWS WOR LDWIDE
© Hydro
Every Can Counts brand at Latitude Festival
in July and at Leeds Festival in August.
Matt Winterburn, head of Corporate Social
Responsibility (CSR) at Carlsberg UK said:
“Joining Alupro and in particular working
with its Every Can Counts programme, helps
us to engage with our customers, suppliers
and consumers on a variety of CSR initiatives,
specifically on the aluminium recycling message.
We aim to demonstrate leadership in
social responsibility and this partnership with
Alupro further underlines our commitment to
being engaged with society.”
Constellium is to sell its
Sabart plant in France
Constellium N.V. is exploring the potential
sale of its plant in Sabart, France. The plant
is a European supplier of hard alloy billets,
and has only limited synergies with Constellium’s
core businesses. With 34 employees, the
facility generated about €16m of the €3.6bn
Aluminium semis
of revenue Constellium generated in 2012.
The company only recently announced that
it is seeking a buyer for its precision castings
operations in Ussel, France.
Befesa sold to Triton
Abengoa has closed the sale of its subsidiary
Befesa to funds advised by Triton, following
the approval by competition authorities.
Spain-based Befesa specialises in the integral
management of industrial waste – steel dust
and salt slags recycling – with plants in Europe,
Middle East and South America.
Befesa had signed an agreement in April
with rolling mill company Novelis to manage
the scrap from its new USD250m aluminium
recycling centre in Nachterstedt, Germany.
Befesa is going to build a new €30m 50,000
tpy aluminium recycling plant in Bernburg,
which will come on stream by the first quarter
of 2014.
■
casting complex dedicated to rolling slab production,
where it delivered safety and quality
improvements and increased casting capacity.
The second project replaced a pusher furnace,
dedicated to homogenising and preheating
slabs before rolling. This should decrease energy
consumption while increasing throughput
and optimising quality.
Two new similar projects, also involving the
modernisation of an additional casting complex
and the replacement of another pusher
furnace, have been launched for start up in
2014.
Noranda to invest USD45m
in aluminium rod mill
Noranda Aluminum will invest USD45m to
expand its operation in New Madrid, Missouri.
The expansion will allow production of redraw
rod for electrical infrastructure applications.
Tennessee-based Noranda will receive
a package of incentives from the state of Missouri
if the company meets job-creation and
investment criteria.
Novelis opens aluminium
rolling operations in Brazil
Novelis Inc. has opened its expanded aluminium
rolling facility in Pindamonhangaba,
Brazil, as it looks to meet growing demand
for flat-rolled products in South America. The
USD340m expansion should boost capacity
at the plant by approx. 50% to more than
600,000 tpy of aluminium sheet. The project
also represents Novelis’ biggest investment in
South America in the past decade. The project
included installing a third cold-rolling mill
at the Pindamonhangaba complex as well as
Mitsubishi Aluminium to boost
capacity in USA and Thailand
Mitsubishi Aluminium Co. will spend ¥1.7bn
(USD20m) to increase production capacity in
the US and Thailand. The company plans to
spend nearly ¥950m on Thermalex, its subsidiary
in Alabama, to install a new press for
processing heat exchanger parts. The factory’s
capacity is expected to rise from its current
capacity of 10,000 tpy to 13,000 tpy by November
2014. The company will also spend
¥790m by August 2014 to boost output at its
Thailand plant by 50% to 7,200 tpy.
Demand for heat exchangers has been
growing as a result of brisk car production in
North America and Southeast Asia, with output
in the two regions expected to continue
growing at an annual rate of 4-6%.
Constellium invests in plant
modernisation at Neuf-Brisach
Constellium N.V. has finalised modernising its
rolling and recycling facility in Neuf-Brisach,
France. The plant is a major supplier and recycler
of rolled aluminium products to the
beverage, food packaging and automotive
markets. Two major projects, representing a
total investment of €23m, upgrade the Neuf-
Brisach facility. The first project modernised a
The Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the primary
aluminium industry. He is also the publisher
of the standard works Alumina Refineries and
Producers of the World and Primary Aluminium
Smelters and Producers of the World. These
reference works are continually updated, and
contain useful technical and economic information
on all alumina refineries and primary
aluminium smelters of the world. They are
available as loose-leaf files and / or CD-ROMs
from Beuth-Verlag GmbH in Berlin.
80 ALUMINIUM · 9/2013

COMPANY NEWS WOR LDWIDE
an ingot casting centre and a pusher furnace
for the operation’s hot-rolling mill.
The investment bolsters Novelis’s position
in the beverage can and aluminium packaging
markets and should allow the company to
take advantage of expected growth in the automotive
sector as well. That’s because Brazil
has set carbon dioxide-emission reduction
targets that should see carmakers looking to
make lighter weight and more fuel-efficient
vehicles.
Pindamonhangaba already has the biggest aluminium
recycling centre in South America and
plans to expand further, increasing the use of
aluminium scrap and developing new alloys
that contain more recycled content.
Brazil recycles 98% of all cans sold compared
with slightly more than 50% in the US.
The expansion comes as Brazil prepares for
the 2014 World Cup and the 2016 Olympics,
which should see increased beverage can consumption
in the country.
On the move
Constellium N. V. appointed Paul Blalock as
head of Investor Relations US. He will be
responsible for managing the company’s communications
and relationships with investors,
analysts and shareholders in the USA.
Alcoa promoted Roy Harvey to COO for
the company’s Global Primary Products (GPP)
business, effective immediately. He will focus
on the day-to-day operations of Alcoa’s 22
aluminium smelters and nine alumina refineries
worldwide, as well as bauxite assets.
Succeeding Harvey as GPP CFO is Leigh Ann
Fisher, who had been group controller for
GPP.
Aditya Birla Group flagship Hindalco Industries
has named Satish Pai the next CEO
of its aluminium business in India.
Alcoa appointed Libby Archell vice
president of Corporate Affairs. Reporting to
Klaus Kleinfeld, Alcoa chairman and CEO,
Ms. Archell will be a member of Alcoa’s
executive council and have responsibility for
communications activities that impact Alcoa’s
reputation, relationships with the media and
employee engagement.
Former Marc Rich & Co. and Glencore
executive Isaac Querub has joined Michael
Armbruester on the board of BlueQuest
Resources. Trading firm BlueQuest Resources
was known as JB Commodities until early July
2013, when ex-Glencore aluminium trader
Josef Bermann ended his association with the
company.
Production of rolled
aluminium in Japan down 5.3%
Japanese production of rolled aluminium
products for the first half of 2013 decreased
by 5.3% from the previous year to 952,406
tonnes. According to Japan Aluminium Association
the result for the first half of calendar
year decreased for the first time in two
years.
■
Suppliers
Potroom insulation measurement
VHE’s enhanced ohmmeter can measure the
electrical resistance between points of different
voltage potential. Conventional ohmmeters
do not have this capability. Much of
the equipment installed in aluminium smelter
potrooms has significant electrical potential
to earth (or ground). The series connection of
the pot busbar system means that pots frequently
have a potential to earth of 1,500 V
dc, and in the most recent systems this can
exceed 2,000 V dc. Alumina dust and metallic
objects can compromise the installed electrical
insulation, and so it is necessary to monitor
insulation performance on a regular basis.
SMS Siemag cold rolling
plant for Nela rolls first strip
Exit area of the new cold rolling mill at Nela
The new six-high cold rolling mill at Northeast
Light Alloy Co. Ltd. (Nela) successfully rolled
its first strip at the end of May. At its production
site in Harbin, in the Chinese province of
Heilongjiang, Northeast Light Alloy now has
an installed production capacity of 85,000 tpy
of aluminium cold strip. The rolling mill features
latest equipment, designed to produce
premium-grade strips. Technological features
of the mill include CVC plus, hot edge spraying
and DS systems. The up to 1,900-mm-wide
strips are rolled to minimum final gauges of
0.1 mm to be used, among others, as input
material in foil production.
In addition to the rolling mill, SMS Siemag
also supplied the equipment for coil preparation
and coil transport as well as the media
supply system.
Luoyang Wanji grants FAC for
two SMS Siemag rolling mills
Following the smooth and efficient commissioning
of two new CVC plus six-high cold
rolling mills, Chinese aluminium producer
Luoyang Wanji Processing C. issued the Final
Acceptance Certificate (FAC) for both mills to
SMS Siemag, Germany.
On cold rolling mill No. 1, the first strip
had already been rolled in 2012. The FAC was
granted before the end of the year, marking
the successful completion of the hot commissioning
phase, with the rolling mill becoming
an integral part of production operations.
This success was repeated at the end of March
this year, when the FAC was also granted for
cold rolling mill No. 2.
Luoyang Wanji’s new production facilities
in the province of Henan in East China now
boast installed production capacities totalling
260,000 tpy. The commissioning of these
© SMS Siemag
ALUMINIUM · 9/2013 81

PATENTE
plants is a milestone in Luoyang Wanji’s entry
into the production of premium aluminium
cold strip in widths of up to 2,150 mm and
final gauges of up to 0.1 mm for a wide range
of applications.
Traditional instruments for this purpose
have been large and cumbersome. VHE’s enhanced
ohmmeter is portable, lightweight and
fitted with comfortable shoulder straps, freeing
both hands to use the measuring probes.
The instrument has a clear digital display and
works just like any other ohmmeter but with
the added ability to measure live conductors.
Batch homogenising plant from
Hertwich commissioned at Dubal
Hertwich Engineering, Austria, has commissioned
a batch homogenising facility and a
cooling station at Dubai Aluminium. The homogenising
plant is the third of its kind that
Hertwich supplied to Dubal. The batch homogenising
facility is designed for extra-fast
heating of billets. A reversing air concept and
regulation by flaps accelerates the heating by
an estimated 20%, and achieves improved
temperature uniformity. The plant is fully automated
and regulated via measured air and
metal temperatures. The same concept also
provides more efficient cooling in the air-cooling
station.
■
Patentblatt Juni 2013
Fortsetzung aus ALUMINIUM 7-8/2013
Aluminiumlegierungsband mit verbesserter
Oberflächenoptik. Hydro Aluminium Deutschland
GmbH, 53117 Bonn, DE. (C22C 21/00, GM
20 2012 012 549, AT: 17.07.2012)
Konditionierung eines Lithobands. Hydro Aluminium
Rolled Products GmbH, 41515 Grevenbroich,
DE. (C23G 1/12, PS 60 2006 029 941,
EP 1896631, WO 2006/122852, AT: 05.04.2006,
EP-AT: 05.04.2006, WO-AT: 05.04.2006)
Schneckenextruder zum kontinuierlichen Extrudieren
von Materialien mit hoher Viskosität.
Norsk Hydro ASA, Oslo, NO. (B21C 23/21,
EP 2 086 697, WO 2008/063076, AT: 19.11.2007,
EP-AT: 19.11.2007, WO-AT: 19.11.2007)
Flügelrahmen einer Schiebetür oder eines
Schiebefensters, der einen verdeckten Pfosten
umfasst. Norsk Hydro ASA, Oslo, NO. (E06B
3/263, EP 1 953 326, AT: 30.01.2008, EP-AT:
30.01.2008)
Halteprofil für ein Rahmenprofil sowie rahmenintegrierte
Absturzsicherung. Gutmann AG,
91781 Weißenburg, DE. (E06B 7/28, GM 20 2013
101 629, AT: 17.04.2013)
Kolben eines Verbrennungsmotors. Honda
Motor Co., Ltd., Tokyo, JP. (F02F 3/02, EP 2 184
477, WO 2009/028128, AT: 20.05.2008, EP-
AT: 20.05.2008, WO-AT: 20.05.2008)
Kolben für Brennkraftmaschinen. KS Kolbenschmidt
GmbH, 74172 Neckarsulm, DE. (F02F
3/16, OS 10 2011 088 066, AT: 09.12.2011)
Gießform eines Kolbens. Mahle International
GmbH, 70376 Stuttgart, DE. (B22D 15/02, OS 10
2011 082 935, AT: 19.09.2011)
Verfahren zur Herstellung eines Zylinders für
einen Zweitaktmotor sowie Gusskern hierfür.
Mahle International GmbH, 70376 Stuttgart, DE.
(F02F 1/22, EPA 2591223, WO 2012/010144,
EP-AT: 05.07.2011, WO-AT: 05.07.2011)
Feueraluminiertes Stahlblech mit hervorragender
Beständigkeit gegenüber thermischer
Schwärzung und Verfahren zu seiner Herstel-
lung. Nippon Steel & Sumitomo Metal Corporation,
Tokyo 100-8071, JP. (C23C 2/12, EPA
2584059, WO 2011/161833, EP-AT: 21.06.2010,
WO-AT: 21.06.2010)
Aus welligen Metallrohren geformte Metallabschnitte.
Novelis, Inc., Toronto, ON M8Z 1J5, CA.
(B65D 19/24, EPA 2585379, WO 2011/160224,
EP-AT: 20.06.2011, WO-AT: 20.06.2011)
Rahmenkonstruktion für Fenster und/oder Türen.
Gutmann AG, 91781 Weißenburg, DE. (E06B
3/30, GM 20 2007 005 388, AT: 12.04.2007)
Verkleidungsmaterial. Showa Denko K.K., Tokio,
JP. (C22C 21/00, OS 10 2012 223 048, AT:
13.12.2012)
Patentblatt Juli 2013
Al-Cu-Li-Legierungsprodukt, das für eine
Luftfahrzeuganwendung geeignet ist. Aleris
Rolled Products Germany GmbH, 56070 Koblenz,
DE. (C22C 21/12, OS 11 2008 002 522,
WO 2009/036953, AT: 16.09.2008, WO-AT:
16.09.2008)
Verfahren und Werkzeug zur zylindrischen
Verformung einer Al-Hülse auf das Kernmaß
des innen liegenden Kunststoffverschlusses,
als Vorbereitung einer diffusionsdichtenden
Pressverbindung innerhalb der beiden Bauteile.
Boehringer Ingelheim International GmbH,
55218 Ingelheim, DE. (B21D 39/04, PS 50 2009
003 891, EP 2340134, WO 2010/040791, AT:
08.10.2009, EP-AT: 08.10.2009)
Verfahren zum Erreichen verbesserter epitaxialer
Qualität (Oberflächenstruktur und Defektdichte)
auf freistehenden (Aluminium, Indium,
Gallium) Nitrid ((Al, In, Ga)N)-Substraten
für optoelektronische und elektronische Vorrichtungen.
Cree, Inc., Durham, N.C., US. (C30B
23/02, EP 2 290 136, AT: 27.06.2001, EP-AT:
27.06.2001)
Verfahren zum Herstellen eines Verbundprofils.
Constellium Switzerland AG, Zürich, CH. (B60M
1/30, PS 10 2006 009 604, AT: 02.03.2006)
Cordierit-Aluminium-Magnesium-Titanat-
Zusammensetzungen und keramische Artikel
damit. Corning Inc., Corning, New York
14831, US. (C04B 35/478, EPA 2594543, EP-AT:
27.06.2007, WO-AT: 27.06.2007)
Baustoffteil aus Si-reicher, Mg-haltiger Al-Legierung
und Herstellungsverfahren dafür. Northeastern
University, Shenyang, Liaoning, CN.
(C22C 21/02, EP 2 172 572, WO 2009/003365,
AT: 30.06.2008, EP-AT: 30.06.2008, WO-AT:
30.06.2008)
Verlötbarer Fluidkanal für einen Wärmetauscher
aus Aluminium. Behr GmbH & Co. KG,
70469 Stuttgart, DE. (B23K 35/28, EPA 2593269,
WO 2012/007452, EP-AT: 12.07.2011, WO-AT:
12.07.2011)
Hochtemperaturbelastbarer, mit Scandium legierter
Al-Werkstoff mit verbesserter Extrudierbarkeit.
Airbus Operations GmbH, 21129
Hamburg, DE. (C22C 21/00, EPA 2598664,
WO 2012/013185, EP-AT: 25.07.2011, WO-AT:
25.07.2011)
Kathodenblock für eine Aluminium-Elektrolysezelle
und ein Verfahren zu seiner Herstellung.
SGL Carbon SE, 65201 Wiesbaden, DE.
(C25C 3/08, EPA 2598675, WO 2012/013772,
EP-AT: 29.07.2011, WO-AT: 29.07.2011)
Verfahren zur Herstellung eines Kathodenblocks
für eine Aluminium-Elektrolysezelle und
einen Kathodenblock. SGL Carbon SE, 65201
ALUMINIUM veröffentlicht unter dieser Rubrik
regelmäßig einen Überblick über wichtige,
den Werkstoff Aluminium betreffende Patente.
Die ausführlichen Patentblätter und auch
weiterführende Informationen dazu stehen
der Redaktion nicht zur Verfügung. Interessenten
können diese beziehen oder einsehen
bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
82 ALUMINIUM · 9/2013

PATENTE
Wiesbaden, DE. (C25C 3/08, EPA 2598673 u. EPA
2598674, WO 2012/013767 u. WO 2012/013769,
EP-AT: 29.07.2011, WO-AT: 29.07.2011)
Gerippter Rohrwärmetauscher aus Aluminium.
Carrier Corp., Farmington, CT 06034, US. (F28F
19/00, EPA 2598821, WO 2012/018536, EP-AT:
21.07.2011, WO-AT: 21.07.2011)
Aluminium-Strangpresslegierung. Aleris Aluminum
Duffel BVBA, Duffel, BE; Aleris Aluminum
Koblenz GmbH, 56070 Koblenz, DE. (C22C 21/
14, PS 600 43 605, EP 1059362, AT: 07.06.2000,
EP-AT: 07.06.2000)
Heizkörper aus extrudiertem Aluminium. Siemens
AG, 80333 München, DE. (F03D 11/00,
EPA 2599999, EP-AT: 02.12.2011, WO-AT:
02.12.2011)
Elektronische Einbruchsicherung für Haustüren,
Wohnungseingangstüren aus Aluminium,
Stahl, Holz und Kunststoff. Nahrson, Wilhelm,
26219 Bösel, DE. (E06B 5/11, GM 20 2013 002
875, AT: 25.03.2013)
Wasserreaktives, Al-basiertes Verbundsmaterial,
wasserreaktiver, Al-basierter, thermisch
gespritzter Film, Verfahren für die Herstellung
eines solchen Al-basierten, thermisch gespritzten
Films und Bestandteil für eine Filmbildungskammer.
ULVAC, Inc., Chigasaki-shi, Kanagawa,
JP. (C23C 4/06, WO 2012 026349, AT:
12.08.2011, WO-AT: 12.08.2011)
Al-Si-Gusslegierung und Verfahren zu ihrer
Herstellung. TU Clausthal-Zellerfeld, 38678
Clausthal-Zellerfeld, DE. (C22C 21/02, PS 50
2008 007 369, EP 1978120, AT: 31.03.2008, EP-
AT: 31.03.2008)
Anordnung zum Kontaktieren eines Aluminium
enthaltenden elektrischen Leiters. Nexans,
Paris, FR. (H01R 4/52, PS 50 2008 007 537, EP
1968161, AT: 16.02.2008, EP-AT: 16.02.2008)
Verwendung einer Eisen-Chrom-Aluminium-
Legierung mit hoher Lebensdauer und geringen
Änderungen im Warmwiderstand. Outokumpu
VDM GmbH, 58791 Werdohl, DE.
(H05B 3/12, PS 50 2008 007 580, EP 2127472,
WO 2008/092420, AT: 15.01.2008, EP-AT:
15.01.2008, WO-AT: 15.01.2008)
Vorbehandlung für Aluminium und Aluminiumlegierungen.
The United States of America as
represented by The Secretary of The Navy, Patuxent
River, Md., US. (C23C 22/05, EP 1 585
848, WO 2004/065642, AT: 21.01.2004, EP-AT:
21.01.2004, WO-AT: 21.01.2004)
Verfahren zum Laser-Lichtbogen-Schweißen
von metallischen Werkstücken, die eine Beschichtung
aus im Wesentlichen Aluminium
und Silizium enthalten. L'Air Liquide, Société
Anonyme pour l'Etude et l'Exploitation des Procédés
Georges Claude, Paris, FR. (B23K 26/14, EP
2 168 710, AT: 22.06.2007, EP-AT: 22.06.2007)
Kolben. Mahle International GmbH, 70376 Stuttgart,
DE. (F02F 3/00, OS 10 2012 200 749, AT:
19.01.2012)
Zusammensetzung der Korrosionsschutzbeschichtung
für eine Zn-haltige Aluminiumlegierung.
United Technologies Corp. (n.d.Ges.d.
Staates Delaware), Hartford, Conn., US. (C23C
22/40, PS 60 2008 016 288, EP 2011899, AT:
24.06.2008, EP-AT: 24.06.2008)
Filter zur Gießung von Teilen aus Al-, Mg-, Cuund
ähnlichen Legierungen. Saint Jean Industries,
Saint Jean d'Ardieres, FR. (C22B 9/02, PS
60 2009 007 347, EP 2274451, WO 2009/122048,
AT: 16.02.2009, EP-AT: 16.02.2009, WO-AT:
16.02.2009)
Gerillte Anode für einen Elektrolysetank. Rio
Tinto Alcan Intl Ltd., Montreal, CA. (C25C 3/12,
EP 2 459 777, WO 2011/015718, AT: 21.07.
2010, EP-AT: 21.07.2010)
Legierung auf Mg-Al-Basis mit Kornverfeiner.
Helmholtz-Zentrum Geesthacht Zentrum für
Material- und Küstenforschung GmbH, 21502
Geesthacht, DE. (C22C 1/03, EP 2 481 822, AT:
01.02.2011, EP-AT: 01.02.2011)
Sandgießverfahren zur Herstellung von Bauteilen
aus Magnesium- oder Aluminiumlegierungen.
Rolls-Royce Deutschland Ltd. & Co KG,
15827 Blankenfelde-Mahlow, DE. (B22D 27/08,
OS 10 2010 025 061, AT: 25.06.2010)
Verfahren zur Herstellung eines Formkörpers
aus Aluminiumlegierung und Formkörper aus
Aluminiumlegierung. Showa Denko K.K., Tokio,
JP. (C22F 1/043, PS 60 2004 038 235, EP
1716265, WO 2005/059195, AT: 17.12.2004,
EP-AT: 17.12.2004, WO-AT: 17.12.2004)
Rohrmaterial aus hochfester Aluminiumlegierung
mit langer Lebensdauer und hoher
Durchhangbeständigkeit. Sapa Heat Transfer
AB, Finspong, SE. (C22C 21/00, EP 1 580 286,
AT: 11.03.2005, EP-AT: 11.03.2005)
Verfahren zur Herstellung eines mit mindestens
einem Hohlraum versehenen Leichtmetall-Bauteils.
Martinrea Honsel Germany GmbH,
59872 Meschede, DE. (B22D 21/04, OS 10 2012
100 458, AT: 20.01.2012)
Magnesiumlegierung. Cast Centre Pty., Ltd.,
St. Lucia, Queensland, AU. (C22C 23/06, PS 60
2006 030 303, EP 1866452, WO 2006/105594,
AT: 04.04.2006, EP-AT: 04.04.2006, WO-AT:
04.04.2006)
Magnesiumlegierung und Herstellungsverfahren
dafür. Kabushiki Kaisha Kobe Seiko
Sho, Kobe-shi, Hyogo, JP. (C22C 23/06, PS 60
2009 007 905, EP 2264200, WO 2009/123084,
AT: 30.03.2009, EP-AT: 30.03.2009, WO-AT:
30.03.2009)
Verfahren zur Herstellung geschmiedeter Bauteile
aus einer TiAl-Legierung und entsprechend
hergestelltes Bauteil. MTU Aero Engines
GmbH, 80995 München, DE. (C21D 1/00, OS 10
2012 201 082, AT: 25.01.2012)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/02, OS 10 2011 115 639, AT: 28.09.2011)
Dichtungsvorrichtung für einen Mittelstoßbereich
einer Schieberahmenanordnung sowie
Schieberahmenanordnung mit einer Dichtungsvorrichtung.
Alcoa Aluminium Deutschland, Inc.,
58642 Iserlohn, DE. (E06B 7/22, EPA 2599946,
EP-AT: 01.10.2012, WO-AT: 01.10.2012)
Verfahren zum Stanznieten von Aluminiumlegierungsblech.
Aleris Aluminum Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514537, EP-
AT: 20.09.2011, WO-AT: 20.09.2011)
Verfahren zum Verbinden von Aluminiumlegierungsblech.
Aleris Aluminum Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514538, EP-
AT: 07.10.2011, WO-AT: 07.10.2011)
AlMgSi-Band für Anwendungen mit hohen
Umformungsanforderungen. Hydro Aluminium
Deutschland GmbH, 41515 Grevenbroich,
DE. (C22F 1/05, EP 2 270 249, AT: 30.06.2009,
EP-AT: 30.06.2009)
Kantenversiegelter Spiegel und Verfahren zu
dessen Herstellung. Hydro Aluminium Rolled
Products GmbH, 41515 Grevenbroich, DE. (G02B
5/08, OS 10 2012 100 293, AT: 13.01.2012)
Verfahren zur Verbesserung der Umformbarkeit
bei der Herstellung von Bauteilen aus
Leichtmetallband. Hydro Aluminium Deutschland
GmbH, 41515 Grevenbroich, DE. (C22F
1/00, PS 196 19 034, AT: 30.04.1996)
Modularer Sonnenkollektor. Hydro Aluminium
Deutschland GmbH, 41515 Grevenbroich, DE.
(F24J 2/20, EP 1 811 245, AT: 15.01.2007, EP-
AT: 15.01.2007)
Korrosionsbeständiger Aluminiumverbundwerkstoff
für eine Fahrzeugkarosserie. Hydro
Aluminium Rolled Products GmbH, 41515 Grevenbroich,
DE. (B23K 20/04, EP 2 302 086, AT:
15.09.2009, EP-AT: 15.09.2009)
Verfahren zur Herstellung eines Kühlkanalkolbens
für Brennkraftmaschinen und derart
hergestellter Kolben. KS Kolbenschmidt
GmbH, 74142 Neckarsulm, DE. (B21K 1/18, EPA
2595771, WO 2012/010285, EP-AT: 18.07.2011,
WO-AT: 18.07.2011)
Plattenförmiger Wärmeüberträger für eine
mindestens eine Wärmeübertragerpaket aufweisende
Kühleinrichtung. Behr GmbH & Co.
KG, 70469 Stuttgart, DE; Mahle Behr Industry
GmbH & Co. KG, 70469 Stuttgart, DE. (F28F
1/32, EPA 2601474, WO 2012/017044, EP-AT:
04.08.2011, WO-AT: 04.08.2011)
Verfahren zum Abtrennen von Kühlschmierstoff
aus Lagerschmiermittel. Hydro Aluminium
Deutschland GmbH, 41515 Grevenbroich,
DE. (C10M 175/00, OS 10 2012 000 588, AT:
16.01.2012)
Verfahren zur Herstellung von Aluminiumkristallen.
Umitomo Metal Mining Co., Ltd., Tokio
105-8716, JP; Tohoku University, Sendai-shi, Miyagi
980-8577, JP. (C30B 29/38, EPA 2594666,
WO 2012/008545, EP-AT: 14.07.2011, WO-AT:
14.07.2011) ■
ALUMINIUM · 9/2013 83

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 Smelting manufactures
Hüttenerzeugnisse
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
84 ALUMINIUM · 9/2013

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 INDUSTRIEOFEN-
UND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
E-Mail: info@inotherm-gmbh.de
Internet: www.inotherm-gmbh.de
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 · 9/2013 85

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
86 ALUMINIUM · 9/2013

SUPPLIERS DIRECTORY
1.14 Aluminium Alloys
Aluminiumlegierungen
2.2 Extrusion equipment
Strangpresseinrichtungen
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
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
see Coil transport systems 3.4
SMS Siemag AG
see Rolling mill technology 3.0
1.17 Protective Clothing
Schutzkleidung
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
• Billet heating furnaces
Öfen zur Bolzenerwärmung
www.mechatherm.com
see Smelting technology 1.5
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
E-Mail: info@oilgear.de
Internet: www.oilgear.de
www.alu-web.de
• Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
• Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
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
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
mfw-maschinenbau.com
• Log/Bolzenlager Handling
• Bolzensäge, Bolzenfügen
see Casthouse (foundry) 1.5
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
Vollert Anlagenbau GmbH
Stadtseestraße 12, D-74189 Weinsberg
Tel. +49 7134 52 220 l Fax +49 7134 52 222
E-Mail intralogistik@vollert.de
Internet www.vollert.de
ALUMINIUM · 9/2013 87

LIEFERVERZEICHNIS
• Packaging equipment
Verpackungseinrichtungen
• Section transport equipment
Profiltransporteinrichtungen
2.4 Heat treatment
Wärmebehandlung
mfw-maschinenbau.com
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
see Coil transport systems 3.4
see Coil transport systems 3.4
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
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 Section handling 2.3
mfw-maschinenbau.com
• Kurzlängensäge automatisiert
• Section store equipment
Profil-Lagereinrichtungen
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• 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
www.mechatherm.com
see Smelting technology 1.5
www.ctisystems.com
see Section handling 2.3
www.alu-web.de
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
kasto@kasto.de / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
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
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
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Heat treatment furnaces
Wärmebehandlungsöfen
INOTHERM INDUSTRIEOFEN-
UND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
see Coil transport systems 3.4
see Section handling 2.3
mfw-maschinenbau.com
• Skip Handling, Spacer
• Kettenförderer
see Section handling 2.3
ERNST REINHARDT GMBH
Güterbahnhofstrasse 1
D-78048 Villingen-Schwenningen
Tel. +49 (0) 7721 8441-0, Fax -44
E-Mail: info@ernstreinhardt.de
Internet: www.ernst-reinhardt.com
88 ALUMINIUM · 9/2013

SUPPLIERS DIRECTORY
• Homogenising furnaces
Homogenisieröfen
2.10 Machining of sections
Profilbearbeitung
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Casthouse (foundry) 1.5
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
• 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
• 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
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Die heating furnaces
Werkzeuganwärmöfen
3
Rolling mill technology
Walzwerktechnik
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
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
2.9 Surface finishing
of sections
Oberflächenveredlung
von Profilen
mfw-maschinenbau.com
• Strahlanlagen
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
see Cold rolling units / complete plants 3.6
www.alu-web.de
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
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 · 9/2013 89

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
90 ALUMINIUM · 9/2013

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
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
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
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
• Surface finishing
of sheets and coils
Oberflächenveredeling
von Blechen und Coils
DEMIS Wide Belt Processing Systems
see Process techn./Automation Techn. 3.10
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
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 · 9/2013 91

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
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Strip shears/Bandscheren
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
• Surface finishing
of sheets and coils
Oberflächenveredeling
von Blechen und Coils
DEMIS Wide Belt Processing Systems
see Process techn./Automation Techn. 3.10
• Trimming equipment
Besäumeinrichtungen
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 INDUSTRIEOFEN-
UND 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
92 ALUMINIUM · 9/2013

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
• Surface finishing
of sheets and coils
Oberflächenveredeling
von Blechen und Coils
Wide Belt Processing Systems
SDV-Santioli AG
Industriestrasse 10 | CH-8157 Dielsdorf | Switzerland
Tel. +41 44 854 0908 | info@demis.ch | www.demis.ch
• Roll Force Measurement equipment
Walzkraftmesseinrichtungen
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
• Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
3.11 Coolant / lubricant
preparation
Kühl-/Schmiermittel-
Aufbereitung
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 · 9/2013 93

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
94 ALUMINIUM · 9/2013

SUPPLIERS DIRECTORY
4 Foundry
Gießerei
4.1 Work protection and ergonomics
Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology
Feuerfesttechnik
4.3 Conveyor and storage technology
Förder- und Lagertechnik
4.4 Mould and core production
Form- und Kernherstellung
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.2 Heat-resistent technology
Feuerfesttechnik
• Refractories / Feuerfeststoffe
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik und Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
Rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
Regelungstechnik
4.17 Environment protection
and disposal
Umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
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 · 9/2013 95

LIEFERVERZEICHNIS
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPCast
TM : the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: 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
96 ALUMINIUM · 9/2013

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 · 9/2013 97

VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
Special: Die internationale
Aluminium-Strangpressindustrie
Wir berichten über Unternehmen und Ausrüster der Strangpressindustrie,
über Anlagentechnik und neue Projekte.
Themen unter anderem: :
• Entwicklung der europäischen Strangpressindustrie 2013
• Innovatives Pressenkonzept HybrEx von SMS Meer
ermöglicht deutliche Energieeinsparung
• IAS weltweit erfolgreich mit induktiver Erwärmungstechnologie
• Neue Strangpresse sichert Gutmann-Standort Neumünster
Weitere Themen
• Die Rolle der Finanzakteure in Rohstoffmärkten:
Verzerren die LME Marktpreise statt Referenzpreise
abzubilden?
• Geschichte der Aluminiumindustrie in Russland
Erscheinungstermin: 02. Oktober 2013
Anzeigenschluss: 18. September 2013
Redaktionsschluss: 09. September 2013
IN THE NEXT ISSUE
Special: The international
aluminium extrusion industry
We will report on companies and equipment partners of the
extrusion industry, with emphasis on plant technology and
new projects. Topics include:
• Development of the European extrusion industry in 2013
• Innovative extrusion press concept HybrEx from
SMS Meer enables significant energy savings
• IAS worldwide successful with induction heating
technology
• New extrusion line for Gutmann subsidiary Nordalu
Other topics
• Understanding the role of financial operators in commodity
markets: Is the LME distorting instead of making
reference market prices?
• History of the aluminium industry in Russia
Date of publication: 02 October 2013
Advertisement deadline: 18 September 2013
Editorial deadline: 09 September 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 8550-2625, 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 98 ALUMINIUM · 5/2012 9/2013

Institute of Forming Technology
and Lightweight Construction
technische universität
dortmund
International Extrusion Event 2013
Retrospect
INTERNATIONAL
CONFERENCE
ON
EXTRUSION
AND
BENCHMARK
th th
October 8 -9 ,
2013
Dortmund, Germany
Scope
The demand for distinct properties and qualities of
extruded profiles pushes extrusion experts and die
makers to the limits of their potential: increasing
complexity of sections, hard alloys, emerging
technologies, and microstructure control are just some of
manufacturers’ everyday concerns.
Key factors for innovation and competitiveness are skilled
engineering analyses and reliable software; however, no
reference community exists for the extrusion analyst and
there is no common base for evaluating commercial code
capabilities.
This two-in-one event provides a unique opportunity:
• to learn about the state-of-the-art of emerging
technologies, innovation and simulation capabilities in
the extrusion of light alloys;
• to acquire guidelines for best process analysis and
product optimization;
• to understand the potential of your current simulation
tool;
Participants
• Extrusion experts (R&D division, production,
managers)
• Academic and industrial researchers
• Die makers (project managers, R&D)
• Software houses, software distributors
• Press and equipment builders
Conference website
www.ice-b.net
Organized by the DIEM Department, University of
Bologna, Italy, and the Institute of Forming Technology
and Lightweight Construction (IUL), TU Dortmund
University, Germany, the last International Conference on
Extrusion and Benchmark (ICEB) was held in Bologna in
September 2011. More than 150 participants from more
than 27 different countries worldwide attended the
conference. 2/3 of the participants were from industry
comprising global players in aluminum production and
extrusion as well as small and medium sized companies
specializing in die building or software development.
Program
th
Wednesday, October 8 , 2013
Conference „Latest Advances in Extrusion
Technology and Simulation“, invited keynotes,
oral presentations of papers
th
Thursday, October 9 , 2013
th
5 Extrusion Benchmark, presentation of the
experiments, presentation and discussion of the
simulation results, oral presentations of papers
Benchmark die 2013
Features:
• Extensive temperature monitoring
• Pressure in the die cavity
• Deflection of the mandrel
Registration
th
Registration (until October 7 , 2013):
Authors and coauthors: 450 € ; delegates: 650 €
th
On desk registration (after October 7 , 2013):
delegates: 700 €
Organizer
Conference chair:
Prof. Dr.-Ing. Dr.-Ing. E.h.
A. Erman Tekkaya
Contact:
Dr.-Ing. Andreas Jäger
Institute of Forming Technology
and Lightweight Construction (IUL)
Technische Universität Dortmund
Baroper Str. 301
D-44227 Dortmund
E-mail: iceb2013@iul.tu-dortmund.de
Phone: +49 231 755-6923
Fax: +49 231 755-2489