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Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-<strong>web</strong>.<strong>de</strong> – PVST H 13410 – Dt. Post AG – Entgelt bezahlt<br />
Norsk Hydro<br />
Volume 84 · January / February 2008<br />
International Journal for Industry, Research and Application<br />
OFFICIAL MEDIA PARTNER<br />
OFFICIAL INTERNATIONAL<br />
MEDIA SPONSOR<br />
Special 2008<br />
The international<br />
smelting industry<br />
Zero fuel baking –<br />
the total heat<br />
recovery concept<br />
Auto control system<br />
for quality casting<br />
Ebner: <strong>de</strong>manding heat<br />
treatment applications<br />
1/2
Billets ready for shipment.<br />
Continuous<br />
Homogenizing Plant<br />
Continuous Homogenizing Plant.<br />
There are many benefits in one-stop shopping –<br />
even for industrial goods. Reliable, cooperative<br />
planning, specifications, which meet exactly your<br />
<strong>de</strong>mands and individual service-packages to operate<br />
on first-class level throughout the whole lifetime of<br />
the plant – this can be realized by one of the most<br />
experienced suppliers: Hertwich Engineering.<br />
Major benefits<br />
Hertwich Engineering is <strong>de</strong>dicated to leading technology<br />
in the aluminum casthouse. We add value<br />
by <strong>de</strong>signing integrated turnkey solutions. From<br />
melting and remelting to testing and packing. The<br />
results are convincing: highest quality of products<br />
at lowest cost-of-ownership. This has been proven<br />
by numerous plants all over the world.<br />
HERTWICH ENGINEERING GMBH<br />
Weinbergerstrasse 6<br />
5280 Braunau, Austria<br />
Leading technology in the aluminum casthouse.<br />
Phone: +43 (0) 7722 806-0<br />
Fax: +43 (0) 7722 806-122<br />
Continuous Homogenizing Plant.<br />
Continuous Homogenizing Plant<br />
Reliable, maximum homogenizing quality,<br />
uniform for all billets<br />
Lowest labour costs, full automation<br />
Best log straightness, no <strong>de</strong>ep surface marks<br />
Extremly reliable operation, little down-time,<br />
low repair costs<br />
Lowest energy consumption, low power ratings<br />
Flexibility of plant layout<br />
More than 80 plants in operation<br />
E-mail: info@hertwich.com<br />
Internet: www.hertwich.com<br />
We will exhibit at:<br />
TMS 2008<br />
137th Annual International<br />
Meeting & Exhibition<br />
Booth No. 708<br />
March 9 to 13<br />
New Orleans, Louisiana, USA<br />
MEETING your EXPECTATIONS
Volker Karow<br />
Chefredakteur<br />
Editor in Chief<br />
Die <strong>Alu</strong>miniumindustrie<br />
im Sog<br />
<strong>de</strong>r Globalisierung<br />
The aluminium industry<br />
in the wake<br />
of globalisation<br />
Die Globalisierung von Wirtschaft, Politik<br />
und Kultur ist in aller Mun<strong>de</strong>. Neu<br />
ist das Phänomen wahrlich nicht, man<br />
<strong>de</strong>nke nur an <strong>de</strong>n einzigartigen Aufstieg<br />
<strong>de</strong>r Fugger-Dynastie im 15./16.<br />
Jahrhun<strong>de</strong>rt, <strong>de</strong>r auf <strong>de</strong>r Entwicklung<br />
eines internationalen Han<strong>de</strong>ls- und<br />
Bergbaugeschäftes grün<strong>de</strong>te. Zweifellos<br />
nehmen sich diese frühen Ausprägungen<br />
<strong>de</strong>r „Globalisierung“ beschei<strong>de</strong>n<br />
aus, verglichen mit <strong>de</strong>nen unserer<br />
Zeit. Interessant ist <strong>de</strong>r historische<br />
Rekurs <strong>de</strong>nnoch: sind es doch gera<strong>de</strong><br />
in jüngster Zeit die Rohstoffkonzerne,<br />
die wie<strong>de</strong>r ins Blickfeld <strong>de</strong>s Wirtschaftsgeschehens<br />
geraten, die zu<strong>de</strong>m<br />
weltumspannend agieren und zu <strong>de</strong>n<br />
höchst bewerteten zählen.<br />
Auch die <strong>Alu</strong>miniumindustrie ist<br />
in diesen Globalisierungstrend einbezogen<br />
– sowohl durch die Stoffströme<br />
vom Bauxitabbau über die Metallproduktion<br />
bis hin zur Vermarktung<br />
<strong>de</strong>r Endprodukte als auch durch <strong>de</strong>n<br />
Konzentrationsprozess, <strong>de</strong>r auf Unternehmensebene<br />
stattfin<strong>de</strong>t und bei<br />
<strong>de</strong>m es die internationalen Minengesellschaften<br />
sind, die <strong>de</strong>rzeit das<br />
Spiel diktieren. Dabei zeigt sich, dass<br />
es entlang <strong>de</strong>r Wertschöpfungskette<br />
in <strong>de</strong>r <strong>Alu</strong>miniumbranche durchaus<br />
unterschiedliche Ausprägungen und<br />
Arten <strong>de</strong>r Globalisierung gibt. Je nach<br />
<strong>de</strong>n spezifischen Wettbewerbsfaktoren<br />
und Marktbedingungen sind ihre<br />
treiben<strong>de</strong>n Impulse bei Hüttenbetrieben<br />
an<strong>de</strong>re als bei Halbzeugwerken<br />
o<strong>de</strong>r in <strong>de</strong>r Endfertigung, wenngleich<br />
das Streben nach Wachstum und Gewinnmaximierung<br />
schlussendlich bei<br />
allen gleich ist.<br />
Welche wirtschaftlichen Triebkräfte<br />
hinter <strong>de</strong>r Globalisierung stehen,<br />
welchen Verän<strong>de</strong>rungen die Branche<br />
in Zukunft ausgesetzt sein wird, ob<br />
integrierte <strong>Alu</strong>miniumkonzerne ein<br />
Auslaufmo<strong>de</strong>ll sind und kleine und<br />
mittlere Unternehmen eine Überlebenschance<br />
in einer globalisierten<br />
Wirtschaftswelt haben – diesen Fragen<br />
geht ein Beitrag von Bruno Rüttimann<br />
in dieser und <strong>de</strong>r nächsten<br />
Ausgabe <strong>de</strong>r ALUMINIUM nach, auf<br />
<strong>de</strong>n an dieser Stelle beson<strong>de</strong>rs hingewiesen<br />
sein soll. Er bil<strong>de</strong>t das Pendant<br />
zu einem Überblicksartikel über die<br />
Branchenaktivitäten <strong>de</strong>s letzten Jahres<br />
nebst einer Reihe technisch orientierter<br />
Beiträge von namhaften Technologiepartnern<br />
und Ausrüstern <strong>de</strong>r<br />
Branche, die sich im Hütten-Special<br />
wie<strong>de</strong>rfin<strong>de</strong>n.<br />
EDITORIAL<br />
Globalisation of the economy, politics<br />
and culture is taking place all over<br />
the world. True, the phenomenon is<br />
not new: one need only think of the<br />
unprece<strong>de</strong>nted rise of the Fugger dynasty<br />
in the 15 th and 16 th centuries,<br />
which was based on the <strong>de</strong>velopment<br />
of an international trading and mining<br />
business. But there is no doubt that<br />
those early forms of ‘globalisation’<br />
were mo<strong>de</strong>st compared with what is<br />
happening in our own times. Still, the<br />
historical prece<strong>de</strong>nt is interesting: in<br />
very recent times it is precisely the<br />
raw materials concerns which are<br />
again at the focus of economic interest,<br />
which moreover are active across<br />
the world, and which are among the<br />
most highly valued.<br />
The aluminium industry too is<br />
involved in this globalisation trend<br />
– both due to the material flows<br />
from bauxite mining, through metal<br />
production and up to the marketing<br />
of end products, and also due to the<br />
concentration process that has been<br />
taking place at corporate level and<br />
in which it is the mining concerns<br />
which now call the shots. In this, it is<br />
evi<strong>de</strong>nt that along the value-addition<br />
chain in the aluminium industry there<br />
are quite different forms and types of<br />
globalisation. In accordance with the<br />
specific competition factors and market<br />
conditions, the driving impulses<br />
for smelter operation are different<br />
from those of semis plants or for finished-goods<br />
production, even though<br />
the striving for growth and maximum<br />
profits is ultimately common to them<br />
all.<br />
What are the economic driving<br />
forces behind globalisation, what<br />
changes will the branch be exposed<br />
to in times to come, are integrated aluminium<br />
concerns an outmo<strong>de</strong>d concept<br />
and do small and medium-sized<br />
enterprises have a chance to survive<br />
in a globalised economic world?<br />
These questions are <strong>de</strong>alt with in a<br />
contribution by Bruno Rüttimann in<br />
this and the next issue of ALUMIN-<br />
IUM, to which particular reference is<br />
ma<strong>de</strong> at this point. It forms the pendant<br />
to a review article on the branch<br />
activities of last year, besi<strong>de</strong>s a series<br />
of technically orientated contributions<br />
by noted technology partners<br />
and equipment suppliers of the aluminium<br />
branch, to be found in the<br />
Special on smelting.<br />
ALUMINIUM · 1-2/2008 3
INHALT<br />
Der ALUMINIUM-Branchentreff <strong>de</strong>s<br />
Giesel Verlags: www.alu-<strong>web</strong>.<strong>de</strong><br />
4<br />
28<br />
48<br />
56<br />
64<br />
EDITORIAL<br />
Die <strong>Alu</strong>miniumindustrie im Sog <strong>de</strong>r Globalisierung .......................3<br />
AKTUELLES<br />
Personen, Unternehmen, Märkte ............................................6<br />
WIRTSCHAFT<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
<strong>Alu</strong>miniumpreise .............................................................. 12<br />
Produktionsdaten <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>miniumindustrie .................. 14<br />
ECCA: Produktion von beschichtetem <strong>Alu</strong>miniumband legt erneut zu 25<br />
Otto Rudolf Fuchs begeht 80. Geburtstag ................................ 27<br />
EEG-Ausgleichsregelung für stromintensive Betriebe: Ersparnisse<br />
von mehr als einer halben Milliar<strong>de</strong> Euro ................................ 28<br />
SPECIAL 2008: DIE INTERNATIONALE<br />
ALUMINIUM-HÜTTENINDUSTRIE<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis ............. 30<br />
MARKT UND TECHNIK<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
Ebner Industrieofenbau: Anspruchsvolle Anwendungen bei<br />
<strong>de</strong>r Wärmebehandlung / Interview mit <strong>de</strong>r Geschäftsführung ........ 66<br />
Siemens liefert Fertigstraße für <strong>Alu</strong>minium-Walzwerk nach China ... 73<br />
UMWELT UND ÖKOLOGIE<br />
Frie<strong>de</strong>nsnobelpreis für IPCC: Ein Quäntchen Ehre auch für<br />
Halvor Kvan<strong>de</strong> ................................................................. 79<br />
BDI-Studie: CO2-Reduzierungspotenzial in NE-Branche nur zu<br />
Lasten <strong>de</strong>r Wettbewerbsfähigkeit möglich ............................... 82<br />
INTERNATIONALE BRANCHENNEWS ................... 83<br />
FORSCHUNG<br />
Englischsprachige Artikel: s. nebenstehen<strong>de</strong>s Verzeichnis<br />
Entstehung von CO2-Emissionen bei <strong>de</strong>r Herstellung von<br />
<strong>Alu</strong>minium-Walzprodukten vor <strong>de</strong>m Hintergrund <strong>de</strong>s nationalen<br />
Emissionshan<strong>de</strong>lssystems ................................................... 96<br />
VERANSTALTUNGEN<br />
RWTH Seminar: Einführung in die Technologie <strong>de</strong>s <strong>Alu</strong>miniums ....102<br />
Termine, Fortbildung ........................................................103<br />
DOKUMENTATION<br />
Neue Bücher ..................................................................100<br />
Literaturservice ...............................................................105<br />
Patente ........................................................................108<br />
Impressum ....................................................................129<br />
Vorschau.......................................................................130<br />
STELLENANGEBOT ...............................................................89<br />
BEZUGSQUELLENVERZEICHNIS .........................112<br />
ALUMINIUM · 1-2/2008
EDITORIAL<br />
The aluminium industry in the wake of globalisation ....................3<br />
NEWS IN BRIEF<br />
People, companies, markets ..................................................7<br />
ECONOMICS<br />
Which globalisation for the aluminium industry? – Part I ............. 16<br />
Marubeni predicts aluminium surplus in 2008 ........................... 23<br />
Rio’s outlook for metals and minerals ..................................... 23<br />
China sets gui<strong>de</strong>lines for domestic aluminium and alumina projects 24<br />
ECCA: production of strip-coated aluminium gains new momentum 25<br />
SPECIAL 2008: THE INTERNATIONAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
Primary aluminium activities at the turn of the year 2007/08 ........ 30<br />
Self-lifting crane mo<strong>de</strong>rnizes ol<strong>de</strong>r potlines .............................. 39<br />
Hydraulic pressing of prebaked ano<strong>de</strong>s for aluminium smelters ...... 40<br />
Zero fuel baking – the total heat recovery concept .................... 44<br />
Best available technology for the fume treatment of ano<strong>de</strong><br />
production plants ............................................................. 48<br />
New generation of FLSmidth Möller direct pot feeding system ...... 54<br />
Metal treatment update ..................................................... 56<br />
Auto control system for quality casting ................................... 61<br />
History of intensive mixing for ano<strong>de</strong> paste used in<br />
aluminium electrolysis ........................................................ 64<br />
MARKETS AND TECHNOLOGY<br />
Ebner Industrieofenbau: Demanding heat treatment applications /<br />
Interview with Ebner management board ....................................66<br />
Siemens supplies new aluminium foil finishing mill .................... 73<br />
<strong>Alu</strong>minium for building and construction in China ...................... 74<br />
European <strong>Alu</strong>minium Renovation Award 2007 .......................... 77<br />
ENVIRONMENT AND ECOLOGY<br />
Articles in German, see in<strong>de</strong>x of contents on the left<br />
Nobel Peace Prize for IPCC: a small slice of glory also for<br />
Halvor Kvan<strong>de</strong> ..........................................................................79<br />
COMPANY NEWS WORLDWIDE<br />
<strong>Alu</strong>minium smelting industry ............................................... 83<br />
Bauxite and alumina activities .............................................. 85<br />
Recycling and secondary smelting ......................................... 86<br />
<strong>Alu</strong>minium semis .............................................................. 88<br />
Suppliers........................................................................ 91<br />
RESEARCH<br />
Articles in German, see in<strong>de</strong>x of contents on the left<br />
Multi-temperature measurement of thermoelectric power for<br />
character isation of solute levels in multi-component industrial<br />
aluminium alloys .............................................................. 92<br />
EVENTS<br />
Review: Incal 2007 – 3 rd International Conference on <strong>Alu</strong>minium ..102<br />
Dates ...........................................................................103<br />
DOCUMENTATION<br />
New books ....................................................................100<br />
Literature service .............................................................105<br />
Imprint .........................................................................129<br />
Preview ........................................................................130<br />
JOB ADVERTISEMENT ...................................... 89<br />
SOURCE OF SUPPLY LISTING ...........................112<br />
ALUMINIUM · 1-2/2008<br />
Inserenten<br />
dieser Ausgabe<br />
List of advertisers<br />
CONTENTS<br />
This issue contains<br />
an enclosure from<br />
Reed Exhibitions<br />
Deutschland GmbH<br />
to which we draw<br />
your kind attention.<br />
66<br />
ABB Switzerland Ltd., Schweiz 31<br />
Alcutec Engineering GmbH 37<br />
Almeq Norway A.S., Norwegen 65<br />
Böhler E<strong>de</strong>lstahl GmbH & Co. KG, Österreich 47<br />
Buss ChemTech AG, Schweiz 55<br />
Coiltec Maschinenvertriebs GmbH 75<br />
Drache Umwelttechnik GmbH 33<br />
Edimet S.p.A., Italien 11<br />
El-Net Consulting AG – Stellenangebot 89<br />
Gesamtverband <strong>de</strong>r <strong>Alu</strong>miniumindustrie e.V. 23<br />
Glama Maschinenbau GmbH 13<br />
Haarmann Holding GmbH 69<br />
Hertwich Engineering GmbH, Österreich 2<br />
High Performance Industrie-Technik GmbH,<br />
Österreich 57<br />
Innovatherm Prof. Dr. Leisenberg<br />
GmbH & Co. KG 53<br />
Inotherm Industrieofen- und<br />
Wärmetechnik GmbH 22, 82<br />
Lucky-Winsun Enterprise Co., Ltd., Taiwan 63<br />
Maschinenfabrik Gustav Eirich<br />
GmbH & Co. KG 43<br />
O.M.S. Impianti Srl, Italien 49<br />
Pa<strong>de</strong>lttherm GmbH 67<br />
Reed Exhibitions Deutschland GmbH 21<br />
Reed Exhibitions India 29<br />
Seco/Warwick S.A., Polen 59<br />
Shanghai Jieru Heavy Industry<br />
Equipment Co. Ltd., China 35<br />
SMS Demag AG 132<br />
5
AKTUELLES<br />
Günter Kirchner<br />
feiert VAR-Jubiläum<br />
Anfang Januar dieses Jahres konnte<br />
Günter Kirchner, Geschäftsführer und<br />
Vorstandsmitglied <strong>de</strong>s Verban<strong>de</strong>s <strong>de</strong>r<br />
<strong>Alu</strong>miniumrecycling-Industrie e.V.<br />
(VAR), Düsseldorf, auf eine 25-jährige<br />
Tätigkeit für <strong>de</strong>n Verband blicken.<br />
Der gelernte Jurist und Rechtsanwalt<br />
wechselte 1983 zur damaligen Vereinigung<br />
<strong>de</strong>r <strong>de</strong>utschen Schmelzhütten<br />
(VDS), nach<strong>de</strong>m er zuvor drei Jahre als<br />
Geschäftsführer <strong>de</strong>s Vereins <strong>de</strong>utscher<br />
Metallhändler (VDM) sein “Handwerk“<br />
in <strong>de</strong>r Welt <strong>de</strong>r NE-Metalle erlernt<br />
hatte. Seit 24 Jahren ist Kirchner<br />
außer<strong>de</strong>m als Generalsekretär in <strong>de</strong>r<br />
Organisation of European <strong>Alu</strong>minium<br />
Refiners and Remelters (OEA) tätig.<br />
Die Redaktion ALUMINIUM gratuliert.<br />
EU plant Emissionshan<strong>de</strong>lspflicht für NE-Metallindustrie<br />
Die EU-Kommission beabsichtigt, das<br />
europäische Emissionshan<strong>de</strong>lssystem<br />
(ETS) auf an<strong>de</strong>re Treibhausgase neben<br />
CO 2 auszu<strong>de</strong>hnen und zusätzliche<br />
Industriebranchen in <strong>de</strong>n Emissionshan<strong>de</strong>l<br />
aufzunehmen. Dazu zählt<br />
auch die Erzeugung und Bearbeitung<br />
von NE-Metallen. So sollen die Produktion<br />
von <strong>Alu</strong>minium (primär und<br />
sekundär) und die Erzeugung und<br />
Bearbeitung von NE-Metallen einschließlich<br />
Gießereien ab 2013 <strong>de</strong>r<br />
Emissionshan<strong>de</strong>lspflicht unterliegen.<br />
Konkret wer<strong>de</strong>n voraussichtlich nur<br />
Anlagen von min<strong>de</strong>stens 20 MW<br />
thermischer Leistung betroffen sein.<br />
Bei Anlagen <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
sollen zusätzlich zum Kohlendioxid<br />
die perfluorierten Kohlenstoffe (PFC)<br />
han<strong>de</strong>lspflichtig wer<strong>de</strong>n.<br />
Mit <strong>de</strong>r Integration in <strong>de</strong>n Emissionshan<strong>de</strong>l<br />
wäre für die <strong>de</strong>utsche<br />
<strong>Alu</strong>miniumindustrie eine zusätzliche<br />
Kostenbelastung verbun<strong>de</strong>n, die im<br />
internationalen Wettbewerb nicht<br />
auf die Kun<strong>de</strong>n überwälzt wer<strong>de</strong>n<br />
kann. Die EU-Kommission sieht die<br />
Integration <strong>de</strong>r NE-Metalle in <strong>de</strong>n<br />
Emissionshan<strong>de</strong>l als einen Lösungsweg,<br />
um einen Ausgleich für <strong>de</strong>n<br />
Strompreiseffekt <strong>de</strong>s Emissionshan-<br />
Foto: Scheben<br />
Hamburger Trimet-Hütte<br />
wie<strong>de</strong>r unter Vollauslastung<br />
Seit En<strong>de</strong> 2007 wie<strong>de</strong>r mit voller Kapazität<br />
unterwegs – die Trimet-Hütte in Hamburg<br />
Schneller als angekündigt arbeitet<br />
die Hamburger <strong>Alu</strong>miniumhütte <strong>de</strong>r<br />
Trimet <strong>Alu</strong>minium AG wie<strong>de</strong>r unter<br />
Volllast. Am 14. Dezember 2007 wur<strong>de</strong><br />
<strong>de</strong>r letzte <strong>de</strong>r 270 Elektrolyseöfen<br />
in Betrieb genommen. Damit hat das<br />
<strong>de</strong>ls zu schaffen. Dazu müssten jedoch<br />
stromintensive Prozesse wie die<br />
Erzeugung von Primäraluminium ein<br />
Vielfaches ihrer direkten CO 2 -Emissionen<br />
kostenlos zugeteilt bekommen,<br />
um einen vollständigen Ausgleich für<br />
die Einpreisung <strong>de</strong>r CO 2 -Zertifikate<br />
in <strong>de</strong>n Strompreis zu erreichen.<br />
Zu Jahresbeginn hat die EU-Kommission<br />
bei <strong>de</strong>r Kompensation <strong>de</strong>s<br />
Strompreiseffektes einen Rückzieher<br />
gemacht. Der betreffen<strong>de</strong> Passus über<br />
die kostenlose Überzuteilung von<br />
Zertifikaten an stromintensive Branchen,<br />
die im internationalen Wettbewerb<br />
stehen, wur<strong>de</strong> aus <strong>de</strong>m Entwurf<br />
<strong>de</strong>r Emissionshan<strong>de</strong>lsrichtlinie gestrichen.<br />
Auch die I<strong>de</strong>e, mittels einer<br />
Besteuerung an <strong>de</strong>r EU-Außengrenze<br />
<strong>de</strong>n Produktionskostennachteil innerhalb<br />
<strong>de</strong>r EU für <strong>Alu</strong>minium und<br />
an<strong>de</strong>re energieintensive Produkte<br />
auszugleichen, hat die EU unter Vorbehalt<br />
gestellt. So ist vor <strong>de</strong>m Start<br />
<strong>de</strong>r dritten Phase <strong>de</strong>s Emissionshan<strong>de</strong>ls<br />
eine Prüfung vorgesehen, ob ein<br />
erhebliches Risiko <strong>de</strong>r Abwan<strong>de</strong>rung<br />
von energieintensiven Branchen infolge<br />
<strong>de</strong>r Kostensteigerungen <strong>de</strong>s<br />
Emissionshan<strong>de</strong>ls zu erwarten ist.<br />
Für die Planungs- und Investitions-<br />
Werk seine ursprüngliche Kapazität<br />
von 130.000 Tonnen Primäraluminium<br />
im Jahr erreicht. Die Produktion<br />
<strong>de</strong>r ersten Öfen war am 9. Mai 2007<br />
feierlich gestartet wor<strong>de</strong>n.<br />
Am 1. Dezember 2006 hatte die Trimet<br />
das stillgelegte Werk von Hydro<br />
übernommen. Im Jahresverlauf wur<strong>de</strong>n<br />
250 Mitarbeiter eingestellt. 2008<br />
will Trimet am Hamburger Standort<br />
25 Mio. Euro in die Mo<strong>de</strong>rnisierung<br />
<strong>de</strong>r Ano<strong>de</strong>nfabrik investieren. Dort<br />
wird ein neuer Brennofen mit größerer<br />
Kapazität in Betrieb gehen, <strong>de</strong>r<br />
die Versorgung <strong>de</strong>r Hütte mit Ano<strong>de</strong>n<br />
sicherstellen wird. Auch <strong>de</strong>r Standort<br />
Essen, wo Trimet eine weitere <strong>Alu</strong>miniumhütte<br />
betreibt, wird dann von<br />
Hamburg aus beliefert wer<strong>de</strong>n.<br />
sicherheit <strong>de</strong>r gesamten NE-Metallindustrie<br />
ist es unabdingbar, bereits<br />
heute die Wettbewerbsfähigkeit durch<br />
geeignete Maßnahmen zu sichern<br />
und diese in <strong>de</strong>r Emissionshan<strong>de</strong>lsrichtlinie<br />
zu verankern. Gemeinsam<br />
mit Eurometaux, <strong>de</strong>m europäischen<br />
Dachverband <strong>de</strong>r NE-Metallindustrie,<br />
for<strong>de</strong>rt die WVM zu allererst eine<br />
wirksame Kompensation <strong>de</strong>s Strompreiseffektes.<br />
Dies könnte durch drei<br />
Optionen geschehen:<br />
• die kostenlose Zuteilung von Zertifikaten<br />
direkt an energieintensive<br />
Unternehmen<br />
• die kostenlose Weitergabe <strong>de</strong>r<br />
Zertifikate an energieintensive Unternehmen<br />
im Rahmen von Langfristverträgen<br />
mit <strong>de</strong>r Energiewirtschaft<br />
• die Rückvergütung von Auktionserlösen<br />
an energieintensive Unternehmen.<br />
En<strong>de</strong> Januar 2008 (Anm.: nach Redaktionsschluss)<br />
legt die EU-Kommission<br />
ihren Vorschlag zur Fortsetzung<br />
<strong>de</strong>s Emissionshan<strong>de</strong>ls ab 2013 vor. Wie<br />
bereits im Vorfeld wird sich die WVM<br />
gemeinsam mit <strong>de</strong>n europäischen<br />
Verbän<strong>de</strong>n in Brüssel und Berlin für<br />
eine Kompensation <strong>de</strong>s Strompreiseffektes<br />
einsetzen. Michael Niese, WVM<br />
6 ALUMINIUM · 1-2/2008
Alcoa sells packaging and<br />
consumer businesses to New-Zealand’s Rank Group<br />
Alcoa has agreed to sell its packaging<br />
and consumer businesses for US$2.7<br />
billion in cash to New Zealand’s Rank<br />
Group Ltd. The transaction is expected<br />
to be completed by the end of the<br />
first quarter 2008. The sale inclu<strong>de</strong>s:<br />
• Closure Systems International, a<br />
global manufacturer of plastic and<br />
aluminium packaging closures and<br />
capping equipment for beverage,<br />
food and personal care customers;<br />
• Consumer Products, a leading<br />
manufacturer of Reynolds Wrap<br />
bran<strong>de</strong>d and private label foil,<br />
wraps and bags;<br />
• Flexible Packaging, a manufacturer<br />
of laminated, printed, and<br />
extru<strong>de</strong>d non-rigid packaging<br />
materials such as pouch, blister<br />
packaging and foil lidding for the<br />
pharmaceutical, food and beverage<br />
markets;<br />
ALUMINIUM · 1-2/2008<br />
Photo: Alcoa<br />
• Reynolds Food Packaging, a business<br />
for products, services and<br />
solutions that improve performance<br />
in the catering, <strong>de</strong>li, bakery,<br />
vending and produce industries.<br />
Reynolds Wrap – soon belonging to Rank Group<br />
These packaging businesses have<br />
some 10,000 employees in 22 coun-<br />
NEWS IN BRIEF<br />
tries around the world and generated<br />
US$3.2 billion in revenues and US$95<br />
million in after-tax operating income<br />
in 2006, representing approximately<br />
ten percent of the company’s revenues<br />
and three percent<br />
of its after-tax operating<br />
income.<br />
Alcoa will continue to<br />
operate its flat-rolled can<br />
sheet products serving<br />
the packaging market.<br />
Rank Group is a New<br />
Zealand-based privately<br />
owned company with<br />
a significant packaging<br />
presence, including:<br />
Carter Holt Harvey, SIG<br />
Holding, and Evergreen<br />
Packaging. Rank Group<br />
has worldwi<strong>de</strong> operations and employs<br />
approximately 17,000 people.<br />
With buy-out of Alcan by Rio Tinto, is Kitimat smelter <strong>de</strong>ad?<br />
Questions are being raised about Rio<br />
Tinto Alcan and its ability to construct<br />
a new smelter in Kitimat given the<br />
huge <strong>de</strong>bt Rio Tinto has amassed in<br />
the Alcan buy-out. After all, Rio Tinto<br />
has paid a 33% premium for the Alcan<br />
shares in the US$38.1bn takeover.<br />
Tom Albanese, who was formerly<br />
Alcan’s chief but then moved to Rio<br />
Tinto, finds himself with a <strong>de</strong>bt load<br />
of about US$47bn. Rio Tinto will sell<br />
some Alcan divisions to yield about<br />
US$8bn, leaving a <strong>de</strong>bt of US$39bn<br />
which still will eat up a staggering<br />
US$2bn a year in interest alone. Industry<br />
experts say that in or<strong>de</strong>r for<br />
the <strong>de</strong>al to work, long term aluminium<br />
prices need to be about US$2,770 a<br />
tonne. However, the current spot price<br />
is about US$2,530 per tonne, and analysts<br />
point out that the long term price<br />
will be around US$1,870 per tonne.<br />
That is, of course, unless Rio Tinto is<br />
able to freeze up the supply and drive<br />
up the price of the product; but that<br />
does not seem likely.<br />
Now, what effect will this latest<br />
move have on the dark clouds that<br />
have hung around Kitimat for years?<br />
If Rio Tinto wants to snare some big<br />
money, it could sell its power producing<br />
facilities to another source. That<br />
would free up nee<strong>de</strong>d cash. The company<br />
could (in or<strong>de</strong>r to get the cash<br />
flow going) simply shut down the<br />
Kitimat smelter as a way to reduce<br />
the source of product and simply sell<br />
power to the BC Hydro grid that hands<br />
them a tidy cash flow. They could also<br />
go ahead with the new smelter, but<br />
that requires investing US$2b and the<br />
question is, where does the money<br />
come from?<br />
Realisation of the Kitimat smelter<br />
is becoming less and less likely as Rio<br />
Tinto takes control of Alcan and looks<br />
to see from where it can milk some<br />
much nee<strong>de</strong>d cash. paw<br />
Based on <strong>Alu</strong>minum Association surveys, U.S. primary aluminium production totalled<br />
2.56 million tonnes in 2007, an increase of 12.2 percent over the 2006 total of 2.28 million<br />
tonnes.<br />
7
AKTUELLES<br />
FORMWERK aktuell<br />
Mit neuem Konzept<br />
und Chefredakteur<br />
Wolfgang Bahle (48) hat zum 1. Januar<br />
2008 die Chefredaktion <strong>de</strong>r im Giesel<br />
Verlag erscheinen<strong>de</strong>n Fachzeitung<br />
FORMWERK aktuell übernommen. Bahle<br />
kommt vom Carl Hanser Verlag, München,<br />
wo er seit 2003 die Redaktion <strong>de</strong>s<br />
Magazins Form + Werkzeug leitete. „Mit<br />
Wolfgang Bahle haben wir einen anerkannten<br />
Fachjournalisten gewonnen, <strong>de</strong>r<br />
sich in <strong>de</strong>r Branche bestens auskennt und<br />
über mehr als zwei Jahrzehnte Erfahrung<br />
als Macher von Fachmedien verfügt“,<br />
betont Dietrich Taubert, Herausgeber von<br />
FORMWERK aktuell. Bahle wird die Fachzeitung<br />
mit eigenem Redaktionsbüro von<br />
München aus betreuen.<br />
Nach <strong>de</strong>r Übernahme hat <strong>de</strong>r Giesel<br />
Verlag <strong>de</strong>n Titel komplett umstrukturiert.<br />
Mit <strong>de</strong>r Berufung Bahles zum<br />
Chefredakteur ist diese Phase nun abgeschlossen.<br />
„Aus vielen Magazinen haben<br />
wir eine aktuelle Fachzeitung für <strong>de</strong>n<br />
Formen- und Werkzeugbau gemacht, die<br />
das Fachzeitschriften-Portfolio unseres<br />
Hauses i<strong>de</strong>al ergänzt“, erläutert Taubert<br />
das neue Konzept.<br />
Der Giesel Verlag verfügt als Herausgeber<br />
renommierter Branchentitel wie<br />
<strong>de</strong>r K-Zeitung, Automotive Materials und<br />
<strong>Alu</strong>minium Praxis etc. über ein Industrienetzwerk<br />
und Branchen-Knowhow, das<br />
für <strong>de</strong>n Auf- und Ausbau von FORM-<br />
WERK aktuell beste Voraussetzungen<br />
bietet. Im Zeitungsformat (A3) stellt<br />
sich das Fachblatt nach <strong>de</strong>m Relaunch<br />
nicht nur optisch im neuen Gewand dar,<br />
son<strong>de</strong>rn wird auch inhaltlich mit einem<br />
noch breiter gefächerten Themenangebot<br />
aufwarten. Im Vor<strong>de</strong>rgrund stehen<br />
Nachrichten und Fachberichte aus <strong>de</strong>r<br />
Welt <strong>de</strong>s Formen- und Werkzeugbaus:<br />
von <strong>de</strong>r Produktentwicklung über <strong>de</strong>n<br />
Werkzeug- und Formenbau bis hin zum<br />
Serienbeginn.<br />
Für 2008 sind sechs Ausgaben mit<br />
einer Auflage von jeweils 12.000 Exemplaren<br />
geplant. Die erste Ausgabe startet<br />
im März. Zu <strong>de</strong>n Abonnenten von FORM-<br />
WERK aktuell gehören Entschei<strong>de</strong>r aus<br />
<strong>de</strong>m Form- und Werkzeugbau sowie<br />
aus <strong>de</strong>n Branchen Kunststoff, Stahl,<br />
NE-Metalle, Automotive, Medical und<br />
Composite.<br />
Evonik verkauft Rütgers Chemicals<br />
Die Evonik Industries AG verkauft<br />
ihre Tochtergesellschaft Rütgers Chemicals<br />
an <strong>de</strong>n Finanzinvestor Triton.<br />
Mit <strong>de</strong>m Abschluss <strong>de</strong>r Transaktion<br />
wird im 1. Quartal 2008 gerechnet.<br />
Rütgers Chemicals, ein international<br />
tätiges Unternehmen <strong>de</strong>r Basischemie,<br />
ist Europas führen<strong>de</strong>r Hersteller<br />
von Erzeugnissen <strong>de</strong>r Teerchemie<br />
sowie globaler Rohstofflieferant<br />
<strong>de</strong>r <strong>Alu</strong>minium- und Stahlindustrie.<br />
2006 erzielte das Unternehmen einen<br />
Umsatz von 650 Mio. Euro, das operative<br />
Ergebnis lag bei rund 60 Mio.<br />
Euro. Für 2007 wird ein Umsatz von<br />
rund 700 Mio. Euro erwartet.<br />
Rütgers beschäftigt <strong>de</strong>rzeit weltweit<br />
950 Mitarbeiter und produziert<br />
in Europa sowie Nordamerika an acht<br />
Chemiestandorten. Am Firmensitz in<br />
Castrop-Rauxel wird die weltweit<br />
größte Raffination von Steinkohlen-<br />
Energieoptimierung durch effiziente<br />
Wärmeübertragung im Glühprozess<br />
Das Drahtwerk Elisental W. Erdmann<br />
GmbH & Co., Neuenra<strong>de</strong>, plant die Errichtung<br />
einer innovativen Abkühl-/<br />
Aufwärmstation, um seinen Energieeinsatz<br />
zu optimieren. Das Unternehmen<br />
hat sich auf die Herstellung<br />
von Drähten aus <strong>Alu</strong>minium- und<br />
Magnesiumlegierungen spezialisiert.<br />
Die Drähte müssen einen Glühprozess<br />
durchlaufen, um die beim Ziehprozess<br />
entstan<strong>de</strong>ne Kaltverfestigung<br />
rückgängig zu machen und dadurch<br />
die Umformbarkeit wie<strong>de</strong>r herzustellen.<br />
Ziel <strong>de</strong>s vom Bun<strong>de</strong>sumweltministerium<br />
(BMU) geför<strong>de</strong>rten Vorhabens<br />
ist es, die Abwärme <strong>de</strong>r Drahtcoils für<br />
die Vorwärmung <strong>de</strong>r kalten Coils vor<br />
<strong>de</strong>m Glühvorgang zu nutzen. Dadurch<br />
kann einerseits Heizenergie eingespart<br />
und zugleich die Ofenkapazität<br />
erhöht wer<strong>de</strong>n, da <strong>de</strong>r Abkühlvorgang<br />
bisher zumeist in <strong>de</strong>r Ofenkammer<br />
stattfand. So soll <strong>de</strong>r Prozess<br />
<strong>de</strong>s Abkühlens aus <strong>de</strong>n Kammeröfen<br />
ausgelagert und zusammen mit <strong>de</strong>m<br />
Prozess <strong>de</strong>s Vorwärmens in einer<br />
neuartigen Anlage vereint wer<strong>de</strong>n.<br />
Die geplante Aufwärm-/Abkühlsta-<br />
teer betrieben, weitere Anlagen stehen<br />
in Belgien und Kanada. Im Geschäftsfeld<br />
Aromatics wer<strong>de</strong>n unter<br />
an<strong>de</strong>rem Peche für die <strong>Alu</strong>minium-<br />
und Stahlindustrie produziert. Wachstumschancen<br />
sieht das Unternehmen<br />
in Asien, Brasilien und Russland.<br />
Triton ist eine unabhängige Private<br />
Equity Gesellschaft, <strong>de</strong>ren Investmentstrategie<br />
auf Unternehmen in<br />
<strong>de</strong>utschsprachigen und nordischen<br />
Län<strong>de</strong>rn Europas zielt. Die Gesellschaft<br />
operiert von Standorten in<br />
Frankfurt, Stockholm und London<br />
aus und verwaltet Fonds mit einem<br />
Volumen von 1,7 Mrd. Euro.<br />
Über <strong>de</strong>n Kaufpreis wur<strong>de</strong> Stillschweigen<br />
vereinbart. Der Verkauf<br />
steht unter <strong>de</strong>m Vorbehalt <strong>de</strong>r Zustimmung<br />
durch die zuständigen<br />
Kartellbehör<strong>de</strong>n.<br />
tion für zunächst ein Glühofenpaar<br />
besteht aus einer Thermokammer,<br />
in <strong>de</strong>r ein Ventilator für eine starke<br />
Luftumwälzung und damit gleichmäßige<br />
Verteilung <strong>de</strong>r Wärme sorgt. Ein<br />
vergleichbares Gebläse befin<strong>de</strong>t sich<br />
in <strong>de</strong>n Glühöfen, das nun nicht mehr<br />
benötigt wird.<br />
Durch die geplante Aufwärm-/Abkühlstation<br />
kann Energie eingespart<br />
wer<strong>de</strong>n. Die Temperatur eines geglühten<br />
Coils beträgt im Schnitt circa<br />
500 °C, das entspricht bei einem<br />
Coilgewicht von zwei Tonnen einem<br />
Wärmeinhalt von ca. 860.000 kJ bzw.<br />
239 kWh. Das Unternehmen schätzt,<br />
dass mit <strong>de</strong>r Kombistation ein kalter<br />
Coil auf eine Temperatur von 150 °C<br />
vorgewärmt wer<strong>de</strong>n kann. Der Wärmeinhalt<br />
wird damit auf rund 233.000 kJ<br />
bzw. 64 kWh erhöht.<br />
Bei erfolgreicher Umsetzung <strong>de</strong>s<br />
Vorhabens will das Unternehmen<br />
auch die übrigen fünf Ofenpaare mit<br />
diesen Stationen ausstatten. Damit<br />
könnten im Werk insgesamt rund<br />
220 Tonnen CO 2 pro Jahr eingespart<br />
wer<strong>de</strong>n. Das BMU för<strong>de</strong>rt das Projekt<br />
mit 42.000 Euro.<br />
8 ALUMINIUM · 1-2/2008
European <strong>Alu</strong>minium Award 2008<br />
An opportunity to be in the limelight<br />
When the ‘<strong>Alu</strong>minium 2008’ tra<strong>de</strong> fair<br />
opens its gates on 23 September, the<br />
international aluminium community<br />
will attend an event that has over<br />
the years <strong>de</strong>veloped to become the<br />
number-one meeting place for the industry<br />
and its applications. More than<br />
700 exhibitors from 40 countries will<br />
present their innovations to 16,000<br />
high-calibre tra<strong>de</strong> visitors from about<br />
100 countries.<br />
The tra<strong>de</strong> fair is a good opportunity<br />
to take part in the competition<br />
for the European <strong>Alu</strong>minium Award<br />
that recognises the highest standards<br />
of excellence in innovations for the<br />
aluminium industry and honours<br />
companies for their outstanding<br />
achievement. The Award competition<br />
is once again being organised by the<br />
<strong>Alu</strong>minium Centrum (Houten / The<br />
Netherlands) in conjunction with the<br />
European and the German aluminium<br />
associations, EAA and GDA, as well<br />
as the organiser of <strong>Alu</strong>minium 2008,<br />
Reed Exhibitions.<br />
The competition is a platform for<br />
companies to <strong>de</strong>monstrate their innovative<br />
capability and offers winners a<br />
‘Put up or shut up’ <strong>de</strong>adline for BHP Billiton<br />
The Takeover Panel has imposed a <strong>de</strong>adline<br />
of 6 February 2008, by which BHP<br />
Billiton has to either announce a firm<br />
intention to make an offer for Rio Tinto<br />
plc un<strong>de</strong>r Rule 2.5 of the UK Takeover<br />
Co<strong>de</strong> or state that it does not intend to<br />
make an offer. If BHP refuses a formal<br />
bid for Rio it will be bound by Rule 2.8<br />
restrictions for six months from the date<br />
of its announcement.<br />
Rio Tinto welcomed this ‘put up or<br />
shut up’ <strong>de</strong>adline. The Board unanimously<br />
rejected BHP’s three-for-one share<br />
offer submitted early in November. “By 6<br />
February, BHP Billiton will have had three<br />
months to make a <strong>de</strong>cision. Rio Tinto<br />
believes it is in the interests of the Group<br />
and its sharehol<strong>de</strong>rs that this period of<br />
uncertainty is brought to an end”, the<br />
company announced. Rio Chairman Paul<br />
ALUMINIUM · 1-2/2008<br />
boost in marketing and exposure. As<br />
one of the 2006 winners, Mr. Cavezzan<br />
from Castaldi Illuminazione, said:<br />
“Inquiries for the product started to<br />
raise higher than ever before.” The<br />
aims for the European <strong>Alu</strong>minium<br />
Award 2008 are as follows:<br />
• To present aluminium to a broad<br />
public as an innovative, mo<strong>de</strong>rn, sustainable<br />
and ecological material<br />
• To honour companies that invest<br />
money and energy in <strong>de</strong>veloping new<br />
and outstanding products<br />
• To present the aluminium industry<br />
as responsible, with an interest in forward-looking<br />
<strong>de</strong>velopment<br />
• To highlight the capability of the<br />
industry regarding new applications<br />
• To add further value to the exhibition<br />
visitors and the exhibition’s <strong>special</strong><br />
programme.<br />
Designers, buil<strong>de</strong>rs, manufacturers<br />
as well as importers and constructors<br />
may participate in the 2008 Award.<br />
The following criteria will be taken<br />
into account in the assessment of the<br />
entries:<br />
• Originality and functionality of<br />
the use of the material: the <strong>de</strong>gree to<br />
Skinner ad<strong>de</strong>d: “Rio Tinto‘s very strong<br />
existing portfolio will create significant<br />
future value for sharehol<strong>de</strong>rs. We have<br />
been very clear as to where we stand and<br />
feel it is time for BHP to do likewise.”<br />
To fend off BHP’s advances Rio announced<br />
at the end of November that<br />
it will increase its 2007 divi<strong>de</strong>nd by 30<br />
percent and raise its divestment target by<br />
50 percent to US$15bn. Furthermore, the<br />
prospect of “an exceptional growth strategy<br />
in iron ore and a strong pricing outlook,<br />
with a conceptual pathway to treble<br />
production to over 600 million tonnes per<br />
annum” (company report) is another cornerstone<br />
to retain in<strong>de</strong>pen<strong>de</strong>nce.<br />
Latest news close to editorial <strong>de</strong>adline:<br />
English papers headline that ‘BHP<br />
prepares to go hostile in Rio bid battle’<br />
(Sunday Telegraph).<br />
NEWS IN BRIEF<br />
which the metal aluminium is used in<br />
an original and useful manner<br />
• Functionality of the product: the<br />
<strong>de</strong>gree to which the part meets both<br />
its primary user function and its technological<br />
function, as a result of the<br />
use of materials, construction and any<br />
ergonomical adjustments<br />
• Design: the <strong>de</strong>gree to which the <strong>de</strong>sign<br />
as a whole achieves a harmonic<br />
unity or a solution – by the construction<br />
of the <strong>de</strong>sign and the <strong>de</strong>tails of<br />
the shape, all this in relation to the<br />
material used<br />
• Durability: in relation to life cycle<br />
costs<br />
• Recycling: the possibility of recycling<br />
the applied materials and the<br />
raw materials used<br />
• Representativeness and promotional<br />
value for aluminium<br />
• The <strong>de</strong>signs must have been taken<br />
into production<br />
• Products or projects must be entered<br />
on one‘s own initiative.<br />
Further information about the European<br />
<strong>Alu</strong>minium Award 2008 and<br />
<strong>de</strong>tails of how to enter are available<br />
on www.aluminium-award.com.<br />
Corus to sell its<br />
smelters in Germany<br />
and The Netherlands<br />
Corus and <strong>Alu</strong>minium Industrial Acquisition<br />
Company Ltd (AIAC) have<br />
signed a non-binding letter of intent<br />
for the proposed acquisition of Corus’<br />
aluminium smelters by an affiliate of<br />
AIAC for an undisclosed sum. Internal<br />
consultation and advice processes<br />
related to the transaction have begun.<br />
A sale and purchase agreement would<br />
only be entered into once these processes<br />
are completed. The proposed<br />
transaction may be subject to certain<br />
external regulatory clearances. The<br />
two smelters are based at Delfzijl in<br />
the Netherlands and at Voer<strong>de</strong> in Germany<br />
and produce over 200,000 tpy of<br />
primary aluminium. The smelters employ<br />
481 people in Germany and 475<br />
people in the Netherlands. paw<br />
9
AKTUELLES<br />
Ernüchterung im Fenstermarkt<br />
Der <strong>de</strong>utsche Fenstermarkt ist 2007<br />
kräftig eingebrochen: Der Absatz sank<br />
um 7,8 Prozent; das Marktvolumen<br />
beläuft sich nun auf 11,7 Mio. Fenstereinheiten<br />
(1 FE = 1,69 m²). Einen<br />
<strong>de</strong>rart massiven Nachfrageeinbruch<br />
hatte die Branche nach <strong>de</strong>m fulminanten<br />
Wachstum 2006 (+ 9,6%) nicht<br />
erwartet. Der Außentürenmarkt ging<br />
um 4,5 Prozent auf 1,1 Mio. Einheiten<br />
(2006: + 5,4%) zurück. Gemessen am<br />
Absatz ist <strong>de</strong>r Umsatz bei Fenster<br />
und Türen aufgrund <strong>de</strong>r steigen<strong>de</strong>n<br />
Werthaltigkeit etwas weniger drastisch<br />
ausgefallen. Soweit die Ergebnisse<br />
einer aktuelle Studie, die von<br />
Branchenverbän<strong>de</strong>n gemeinsam mit<br />
<strong>de</strong>m Marktforschungsinstitut Heinze<br />
erarbeitet wur<strong>de</strong>n. Für 2008 wird sowohl<br />
im Fenster- als auch im Außentürenmarkt<br />
wie<strong>de</strong>r eine mo<strong>de</strong>rate<br />
Belebung erwartet.<br />
Zum Jahreswechsel gab speziell<br />
<strong>de</strong>r Wohnungsbau ein düsteres Bild<br />
ab. Wie befürchtet brachen aufgrund<br />
<strong>de</strong>s Wegfalls <strong>de</strong>r Eigenheimzulage<br />
und <strong>de</strong>r Mehrwertsteuererhöhung<br />
Anfang 2007 die Baufertigstellungs-<br />
daten massiv ein. Doch auch die<br />
vorwiegend energetische Mo<strong>de</strong>rnisierung<br />
und Renovierung von Wohngebäu<strong>de</strong>n<br />
konnte sich wi<strong>de</strong>r Erwarten<br />
<strong>de</strong>m Abwärtssog nicht entziehen.<br />
Diese bei<strong>de</strong>n Negativeffekte konnten<br />
auch durch die Nachfragebelebung<br />
im Nicht-Wohnbau nicht ausgegli-<br />
<strong>Alu</strong>minium-Rahmenmaterial konnte sich<br />
2007 <strong>de</strong>m Absatzeinbruch bei Fenstern<br />
und Türen entziehen<br />
chen wer<strong>de</strong>n, so dass 2007 <strong>de</strong>r Fenstermarkt<br />
in <strong>de</strong>n Sog <strong>de</strong>r negativen<br />
Bauinvestitionsentwicklung geriet.<br />
„Diese Marktentwicklung ist umso<br />
unerwarteter, als die in <strong>de</strong>r breiten Öffentlichkeit<br />
geführte Diskussion über<br />
Energieeinsparung und Klimaschutz<br />
sowie die exorbitant steigen<strong>de</strong>n<br />
Energie- und Strompreise eine <strong>de</strong>utliche<br />
Nachfragebelebung nach energieeffizienten<br />
Fenstern hätten erwarten<br />
lassen“, kommentierte Ulrich<br />
Tschorn, Geschäftsführer <strong>de</strong>s Verban<strong>de</strong>s<br />
<strong>de</strong>r Fenster- und Fassa<strong>de</strong>nhersteller<br />
in Frankfurt die Marktlage.<br />
Der erfreuliche Anstieg im Industriebau,<br />
bei Büroimmobilien, Lagergebäu<strong>de</strong>n<br />
und Hotels brachte eine<br />
Verschiebung <strong>de</strong>r Rahmenmaterialanteile<br />
zugunsten von <strong>Alu</strong>minium<br />
(+5,0%).<br />
Für 2008 erwartet die Branche ein<br />
beschei<strong>de</strong>nes Wachstum von 1,1 Prozent<br />
auf 11,8 Mio. Fenstereinheiten.<br />
Für <strong>de</strong>n Außentürenmarkt wird ein<br />
kleiner Zuwachs von 0,4 Prozent prognostiziert.<br />
Die Zuversicht auf eine<br />
leichte Belebung <strong>de</strong>s Marktes stützt<br />
sich auf die steigen<strong>de</strong> Nachfrage im<br />
Bereich <strong>de</strong>r energetischen Gebäu<strong>de</strong>mo<strong>de</strong>rnisierung<br />
im privaten und vor<br />
allem im öffentlichen Immobilienbestand.<br />
Deutschland 2007<br />
Sinken<strong>de</strong>r Energieverbrauch trotz Wirtschaftswachstum<br />
Der Energieverbrauch ist 2007 in<br />
Deutschland mit 13.842 Petajoule auf<br />
das niedrigste Niveau seit <strong>de</strong>r Wie<strong>de</strong>rvereinigung<br />
abgesunken. Gegenüber<br />
2006 beträgt <strong>de</strong>r Rückgang 5,0 Prozent,<br />
gegenüber 1990 7,1 Prozent, so<br />
die aktuellen Zahlen <strong>de</strong>r Arbeitsgemeinschaft<br />
Energiebilanzen.<br />
10 ALUMINIUM · 1-2/2008<br />
Foto: www.alufenster.at<br />
Bei einem Anstieg <strong>de</strong>r Wirtschaftsleistung<br />
um 2,4 Prozent gegenüber <strong>de</strong>m<br />
Vorjahr hat sich <strong>de</strong>r spezifische Primärenergieverbrauch<br />
2007 unbereinigt<br />
(ohne Witterungseffekte) um 7,5<br />
Prozent und bereinigt um rund sechs<br />
Prozent verbessert. Der spezifische<br />
Energieverbrauch (unbereinigt) hat<br />
sich seit 1990 damit um rund zwei<br />
Prozent pro Jahr verringert.<br />
Mit <strong>de</strong>m rückläufigen Energieverbrauch<br />
sind auch die energiebedingten<br />
CO 2 -Emissionen <strong>de</strong>utlich gesunken.<br />
Nach ersten Abschätzungen <strong>de</strong>s<br />
Bun<strong>de</strong>sministeriums für Wirtschaft<br />
sind sie 2007 gegenüber <strong>de</strong>m Vorjahr<br />
um 3,6 Prozent gesunken; gegenüber<br />
1990 beträgt <strong>de</strong>r Rückgang 19,3 Prozent.<br />
Damit ist Deutschland auf gutem<br />
Weg, seine Kyoto-Verpflichtung (Reduktion<br />
um 21 Prozent bis 2012) zu<br />
erfüllen.
<strong>Alu</strong>minium India 2008 makes impressive stri<strong>de</strong>s<br />
<strong>Alu</strong>minium India 2008, the International<br />
Conference and Exhibition will<br />
be held in Mumbai from 22 to 24 February<br />
in or<strong>de</strong>r to address the needs<br />
of the Indian aluminium industry in<br />
the context of global markets and new<br />
technologies. The tra<strong>de</strong> show has confirmed<br />
participation of about 70 exhibitors,<br />
which will display the latest<br />
technology, trends and applications<br />
from across the world. A formidable<br />
international participation already<br />
pegged at 60 percent leaves nothing<br />
to imagine. Tra<strong>de</strong> visitors to the show<br />
can very well expect a world of aluminium<br />
on and can benefit in an atmosphere<br />
charged with productivity.<br />
The show has the support of the<br />
Ministries of Mines, Science and<br />
Technology as well as the leading associations<br />
like Fe<strong>de</strong>ration of Mineral<br />
and Metal Industries, Cable and Conductors<br />
Manufacturer Association<br />
promises to be the most comprehensive<br />
platform on aluminium in India.<br />
A host of visitor viz CEO’s, directors,<br />
ALUMINIUM · 1-2/2008<br />
plant and process managers, entrepreneurs,<br />
consultants, senior bureaucrats,<br />
stu<strong>de</strong>nts amongst others are expected<br />
to visit and witness the future<br />
unfold. The silver lining is the high<br />
profile inauguration of the show by<br />
the Minister of Mines accompanied<br />
by the Secretary, Mines and other<br />
senior government officials from various<br />
states. The cutting edge international<br />
conference Alcastek will see a<br />
large number of foreign participants<br />
and presentations on best practices<br />
across the world. Mr. G. Kirchner,<br />
Chairman of the Global <strong>Alu</strong>minium<br />
Recycling Committee from Germany,<br />
will speak on the ‘Current and Future<br />
Perspectives of Global Recycling of<br />
<strong>Alu</strong>minium’. Director of Vedanta Resources,<br />
Mr. S. K. Timotia will speak<br />
on the related issue of ‘Current Energy<br />
and Environmental Issues in <strong>Alu</strong>minium<br />
Industry ‘.<br />
<strong>Alu</strong>minium India 2008 will host<br />
the technical session which is being<br />
divi<strong>de</strong>d in various segments to meet<br />
NEWS IN BRIEF<br />
the <strong>de</strong>mands of the industry. The plenary<br />
session is going to discuss the<br />
global trends by the lea<strong>de</strong>rs of the aluminium<br />
industry. Mr. P. Suri, Presi<strong>de</strong>nt,<br />
Balco, India will be addressing<br />
the plenary session ‘an overview of<br />
the industry’; he has been associated<br />
with the industry almost all his life.<br />
The metal has varied uses in almost<br />
every industry, from aircrafts to automobiles,<br />
from power cables to foils.<br />
One reason is that aluminium can be<br />
fashioned into countless shapes in a<br />
variety of applications because of its<br />
basic malleable qualities. <strong>Alu</strong>minium<br />
is gaining ground in the transportation<br />
industry because of its light weight<br />
which translates into higher payloads<br />
and lower fuel consumption. Indian<br />
railways is increasing its consumption<br />
of aluminium in railway wagons.<br />
The aerospace industry is another<br />
large consumer of aluminium. The<br />
automotive sector has also increased<br />
use of the metal in various body and<br />
engine parts.<br />
11
WIRTSCHAFT<br />
12 ALUMINIUM · 1-2/2008
WIRTSCHAFT<br />
Produktionsdaten <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>miniumindustrie<br />
Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**<br />
Produktion<br />
(in 1.000 t)<br />
+/in<br />
% *<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Produktion<br />
(in 1.000 t)<br />
+/in<br />
% *<br />
Produktion<br />
(in 1.000 t)<br />
+/in<br />
% *<br />
Nov 41,9 -17,9 73,0 11,8 163,9 8,7 52,1 10,2<br />
Dez 42,8 -10,1 61,6 12,9 124,1 1,2 34,6 10,2<br />
Jan 07 40,9 -4,5 70,7 8,1 147,8 -2,7 51,1 12,6<br />
Feb 37,1 -4,1 71,1 9,2 154,7 -2,5 49,9 8,3<br />
Mrz 41,5 -3,8 75,2 -4,7 177,1 -0,6 54,7 5,3<br />
Apr 41,8 -1,4 67,0 7,1 158,1 6,0 47,3 10,5<br />
Mai 46,4 7,0 71,4 5,0 166,5 -2,5 50,8 2,2<br />
Jun 46,5 7,8 73,6 12,0 164,8 0,7 51,7 8,1<br />
Jul 48,7 8,1 72,5 13,2 167,1 1,5 53,3 9,8<br />
Aug 49,0 8,5 63,5 6,7 164,8 -1,1 51,5 7,2<br />
Sep 47,0 9,8 69,7 4,1 156,7 -2,3 50,2 -1,8<br />
Okt 50,2 13,8 74,1 14,1 170,7 0,4 55,4 6,0<br />
Nov 49,7 18,5 73,0 0,0 155,8 -4,9 53,7 3,1<br />
* gegenüber <strong>de</strong>m Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung <strong>de</strong>s Gesamtverban<strong>de</strong>s <strong>de</strong>r <strong>Alu</strong>miniumindustrie (GDA), Düsseldorf<br />
Primäraluminium<br />
Walzprodukte > 0,2 mm<br />
Sekundäraluminium<br />
Press- und Ziehprodukte<br />
14 ALUMINIUM · 1-2/2008
ECONOMICS<br />
A normative analysis exploring alternative business mo<strong>de</strong>ls<br />
Which globalisation for<br />
the aluminium industry? – Part I<br />
B. G. Rüttimann, Singen<br />
The aluminium industry is at<br />
present un<strong>de</strong>rgoing a fundamental<br />
transformation. After the concentration<br />
of vertically integrated<br />
aluminium concerns we are now<br />
experiencing on the one hand the<br />
formation of big aluminium mining<br />
groups and on the other hand<br />
the creation of process-technology<br />
<strong>special</strong>ised groups for the semifinished<br />
product sector. All this<br />
has to be seen un<strong>de</strong>r a rationale<br />
that aims to control raw material<br />
sources and to respond to<br />
increased competition in search<br />
of maximizing profits. Which are<br />
the economic mo<strong>de</strong>ls governing<br />
the ongoing logic of globalisation?<br />
What will the present aluminium<br />
industry system look like in the<br />
future? Are the fully integrated<br />
aluminium groups a run-out mo<strong>de</strong>l?<br />
Do small and medium-sized<br />
companies still have a chance to<br />
survive? The following contribution<br />
analyses the different competitive<br />
systems within the valueaddition<br />
chain of the aluminium<br />
industry in or<strong>de</strong>r to explore the<br />
rationale of alternative business<br />
mo<strong>de</strong>ls within the present globalisation<br />
phenomenon.<br />
Hardly a day passes without news or<br />
rumours about friendly or hostile takeovers<br />
or mergers in the aluminium<br />
and other industries. In the attempt to<br />
maximizing profits un<strong>de</strong>r the umbrella<br />
of increased competition and limited<br />
growth in advanced countries on the<br />
one hand, but with a view to sustained<br />
growth in emerging economic areas on<br />
the other hand, a new era of company<br />
gigantism has ma<strong>de</strong> its appearance. To<br />
secure access to raw material sources<br />
for the supply of the fast-growing new<br />
economies, combined with their highly<br />
competitive labour cost structure,<br />
the BRIC (Brazil, Russia, India, China)<br />
countries together with the leading<br />
Western technologically<br />
advanced companies<br />
will establish<br />
a new economic<br />
world or<strong>de</strong>r.<br />
In the aluminium<br />
industry, the merger<br />
of Alcan with <strong>Alu</strong>suisse<br />
and Pechiney<br />
gave the initial impetus<br />
for the creation<br />
of a new industrial<br />
logic. The Alcoa-<br />
Kaiser merger followed.<br />
Similar aims,<br />
but with a different<br />
focus, were the<br />
intention behind<br />
the Hoogovens and<br />
British Steel merger<br />
which formed the Corus company.<br />
Norsk Hydro has grown with the<br />
VAW take-over and, in a second step,<br />
concentrated on aluminium activities.<br />
Alcoa Extrusion and Sapa have<br />
formed the largest extrusion conglomerate<br />
and Mittal took over Alcan’s<br />
Novelis spin-off. And now, after<br />
the Rusal, Sual and Glencore merger<br />
forming Russian UC Rusal aluminium<br />
giant, we have seen the Rio Tinto mining<br />
giant successfully bidding for the<br />
aluminium giant Alcan [1,2]. Out of<br />
the originally 12 integrated big aluminium<br />
concerns that existed in the<br />
1980s, today it seems that not one of<br />
the Western concerns will survive<br />
[3].<br />
The names and configurations of<br />
companies are changing continuously<br />
with the intention to form an i<strong>de</strong>al<br />
business constellation which will<br />
gain competitive advantages within<br />
the global market challenge, consistent<br />
with the doctrine of maximizing<br />
profits in each case. In this context<br />
the word ‘globalisation’ is used all<br />
the time and often applied as a catchword<br />
indifferently, without having<br />
perceived the subtle differences of<br />
Fig. 1: The Business Typology Matrix [4]<br />
patterns regarding this phenomenon.<br />
Moreover, the word globalisation still<br />
makes many employees feel uneasy,<br />
since they fear becoming victims of<br />
company mergers and loosing their<br />
jobs. In what follows, we will discover<br />
that globalisation is not always the<br />
same thing and that strategies have to<br />
follow different schemes corresponding<br />
to the intrinsic nature of each business.<br />
This paper aims to outline some<br />
structured thinking that will help to<br />
un<strong>de</strong>rstand the future industrial logic<br />
of the changing aluminium industry.<br />
Characteristics of<br />
the aluminium business<br />
To gain insight into the globalisation<br />
phenomenon, we have at first to<br />
un<strong>de</strong>rstand the intrinsic nature of a<br />
business. A business system is mainly<br />
composed of:<br />
• the transaction object, i. e. the<br />
product or service<br />
• the supply and <strong>de</strong>mand structure,<br />
with the related transaction<br />
scheme, and<br />
• the operating configuration of<br />
supply.<br />
16 ALUMINIUM · 1-2/2008<br />
Illustrations: Rüttimann
The backward <strong>de</strong>terminants themselves<br />
which influence product characteristics,<br />
market structure, and <strong>de</strong>termine<br />
the business classification,<br />
and finally the operating configuration,<br />
are:<br />
• value of the product<br />
• transport costs and related range<br />
of distribution<br />
• production factors in terms of<br />
cost drivers<br />
• <strong>de</strong>mand profile and<br />
• supply structure.<br />
These main <strong>de</strong>terminants characterise<br />
each business type within an<br />
industrial system. Certain combinations<br />
of these <strong>de</strong>terminants reveal<br />
clear patterns for each business type.<br />
The representation of product-characteristics<br />
(differentiated or not) on<br />
one axis and market-structure (oligopolistic<br />
or fragmented) on another<br />
axis within a matrix, leads finally to<br />
the following landscape of basic business<br />
types [4]:<br />
• commodities<br />
• <strong>special</strong>ties<br />
• standards<br />
• convenience.<br />
Fig. 1 presents a clear, systematic and<br />
structured view with which to classify<br />
businesses roughly into types. It goes<br />
without saying that mixed types may<br />
exist. The ‘commodity’ type of business<br />
(e. g. metal ore or wheat) comprises<br />
all kind of goods listed in efficient<br />
marketplaces such as commodity exchanges,<br />
where world market prices<br />
apply. The ‘<strong>special</strong>ty’ type of business<br />
(e. g. electronics or automobiles) embraces<br />
those durables and consumables<br />
goods with a distinctive brand,<br />
and are thus governed by an imperfect<br />
competition. The ‘standards’ type of<br />
business (e. g. cement or extrusions)<br />
covers intermediate or semi-finished<br />
products with a rather polypolistic<br />
supply structure. The ‘convenience’<br />
type of business (e. g. clothing, but also<br />
hotels) embraces most of the products<br />
we come across sold in retail stores<br />
in a very fragmented market to reach<br />
the end user, and from the supply si<strong>de</strong><br />
represents an imperfect or monopolistic<br />
competition.<br />
Let us now try to fit the aluminium<br />
technologies into this matrix. Bauxite<br />
mining is an ore extracting operation<br />
often performed by big vertically in-<br />
ALUMINIUM · 1-2/2008<br />
tegrated aluminium companies or<br />
multinational mining groups, and is<br />
characterised by a clear oligopolistic<br />
market structure. By <strong>de</strong>finition the<br />
differentiation aspect of a commodity<br />
does not exist, except perhaps in relation<br />
to ore content. The same applies<br />
to calcined alumina. The outcome of<br />
the smelting process is primary aluminium,<br />
tra<strong>de</strong>d as ingots on commodity<br />
exchanges mainly as the 99,7%<br />
gra<strong>de</strong>. For primary aluminium too we<br />
have the same oligopolistic structure<br />
composed of MNEs (Multi-National<br />
Enterprises) with some in<strong>de</strong>pen<strong>de</strong>nt<br />
SMEs (Small Medium Enterprises) as<br />
exceptions. We can classify all these<br />
goods as belonging to the commodity<br />
type of business, goods flowing from<br />
their natural origin to the big conversion<br />
centres. The world of semi-fabricated<br />
products is mainly composed<br />
of the technologies rolling, extrusion,<br />
castings, forgings, and thin-foil rolling.<br />
Although often<br />
these plants belong<br />
to MNEs, the operating<br />
configuration<br />
has a more fragmented<br />
structure<br />
imposed by the <strong>de</strong>sire<br />
for proximity<br />
to the customers;<br />
MNEs try to serve<br />
a wi<strong>de</strong>r geographical<br />
area by setting<br />
up a network of<br />
plants. The reasons<br />
for fragmentation<br />
originate from the<br />
cumbersome shape<br />
of the products but<br />
also the need to interact<br />
with customers,<br />
so resulting in a<br />
more regionally orientated business.<br />
The fragmentation of the business<br />
favours the concomitance of SMEs<br />
mainly in the sectors of extrusion,<br />
casting and forging. For example, in<br />
the case of extrusion SMEs make up<br />
50% of the plants [3].<br />
All these technologies can be classified<br />
as belonging to the standards<br />
type of business. These are intermediate<br />
goods with a low <strong>de</strong>gree of product<br />
differentiation. We can even classify<br />
the transaction object rather as a<br />
service than just a physical product.<br />
ECONOMICS<br />
In<strong>de</strong>ed, the customer asks primarily<br />
three questions: “Can you manufacture<br />
this product? When can you supply<br />
it? How much will it cost?”, so extrusion<br />
companies do not supply just<br />
a product, but also perform a service<br />
by putting their production capacities<br />
to the service of their customers and<br />
trying to achieve the shortest <strong>de</strong>livery<br />
time, accurate punctuality and specification-conforming<br />
quality [5]. In the<br />
aluminium industry we can sometimes<br />
also observe downstream integration<br />
in the value-addition chain, such as<br />
ready-to-fit components or systems<br />
for the building industry. These products<br />
have already a quite advanced<br />
differentiation <strong>de</strong>gree regarding the<br />
solution proposed. On the other hand<br />
the <strong>de</strong>gree of concentration from the<br />
supply point of view may vary. Nevertheless,<br />
we can classify such sectors as<br />
belonging in-between the <strong>special</strong>ties<br />
type of business.<br />
Fig. 2: <strong>Alu</strong>minium technologies within the Business Typology Matrix<br />
From Fig. 2 we can see that the products<br />
(or technologies) of the aluminium<br />
industry rather belong to the<br />
commodities and standards type of<br />
business; this seems to be reasonable<br />
due to the fact that the transaction<br />
type is rather a B2B than a B2C.<br />
The different perceivable<br />
patterns of globalisation<br />
Globalisation is not always one and<br />
the same thing [4]. This is also observable<br />
in the aluminium in- �<br />
17
ECONOMICS<br />
Fig. 3: The Globalisation Type Matrix [4]<br />
dustry. In fact, once having classified<br />
the businesses, the question is how<br />
globalisation is influenced by each<br />
business type, or rather how globalisation<br />
of the business evolves in each<br />
business type and according to which<br />
pattern. Analysing the business types,<br />
it emerges that the operating configuration<br />
<strong>de</strong>termined by the business is<br />
a major <strong>de</strong>terminant for the globalisation<br />
type. The intrinsic logic reveals<br />
two main types [4]:<br />
• type 1: material (or physical)<br />
globalisation for commodities<br />
and <strong>special</strong>ties<br />
• type 2: immaterial (or financial)<br />
globalisation for the standards<br />
and convenience.<br />
The difference is substantial. Products<br />
of businesses following type 1<br />
globalisation could ultimately be produced<br />
within a single plant operating<br />
configuration and shipped physically<br />
worldwi<strong>de</strong>, whereas products of businesses<br />
following a type 2 globalisation<br />
are produced locally for the local<br />
market. MNEs will have in this case<br />
a network of local companies by FDI<br />
(Foreign Direct Investments) and the<br />
business i<strong>de</strong>a is to exploit the specific<br />
know-how in doing business. In this<br />
fragmented market they have to buy<br />
or set up new enterprises to increase<br />
market share. But for type 1 globalisation<br />
we have to distinguish between<br />
commodities and <strong>special</strong>ties. Let us<br />
call type 1a the ‘globalisation of commodities’;<br />
through the listing on efficient<br />
market places like commodity<br />
exchanges, this represents the pure<br />
example of a globalisation of business.<br />
Nobody can escape from this type of<br />
globalisation because its effects are<br />
spreading all over the world. For type<br />
1b ‘globalisation of <strong>special</strong>ties’ the<br />
product characteristics are unique<br />
and therefore – to some extent – the<br />
price can be fixed by the supplier<br />
taking into account the value for the<br />
Fig. 4: Type 1a or globalisation of commodities<br />
customer. This is due to the possibility<br />
of product differentiation within<br />
the competitive system. For type 2<br />
globalisation this distinction between<br />
subtypes is not necessary. In<strong>de</strong>ed, according<br />
to Chamberlain markets not<br />
involving material (physical) flows of<br />
products over a certain distance represent<br />
a local monopoly. So there is<br />
no need to differentiate globalisation<br />
patterns between standard and convenience<br />
product types.<br />
Are there any drivers able to upset<br />
this apparently stable situation? Yes,<br />
there is one. If the difference in price<br />
for the same goods in different economies<br />
exceeds a certain threshold, exports<br />
can temporarily become possible<br />
also for products following type 2 globalisation.<br />
We may call this ‘economic<br />
arbitrage’. In these cases we can also<br />
observe a material flow of products<br />
within the type 2 globalisation characterised<br />
businesses; let us call this<br />
type 1c globalisation ‘opportunistic<br />
or low-cost globalisation’. Typical are<br />
the exports of low-cost countries such<br />
as China to the advanced economies.<br />
But if a price difference also exists in<br />
different economies for the salaries<br />
of white-collar jobs – and the skills<br />
are equivalent – then it is also possible<br />
that enterprise functions such<br />
as R&D, call centres or accounting are<br />
outsourced to low-cost countries like<br />
India; let us call this type 3 globalisation<br />
the ‘globalisation of human factor<br />
or service’.<br />
Fig. 3 shows all the types of globalisation<br />
within a matrix which allows<br />
a rough i<strong>de</strong>ntification of the type of<br />
globalisation and, from that, the possible<br />
evolution or competitive issues<br />
to face within a certain business. It<br />
18 ALUMINIUM · 1-2/2008
goes without saying that mixed types<br />
may exist.<br />
Moreover, these different globalisation<br />
types also follow different economic<br />
laws. Type 1a is characterised<br />
by global price building at commodity<br />
exchanges and mainly unidirectional<br />
material flows from countries of origin<br />
to the countries of transformation<br />
(Fig. 4). The preference for a raw material<br />
such as aluminium compared<br />
to another such as steel <strong>de</strong>pends on<br />
the ‘latent value’ of a specific resource<br />
compared to the substitute resource<br />
[4]. This also takes into consi<strong>de</strong>ration<br />
the ecological impact or the end-ofcycle<br />
aspects.<br />
Globalisation type 1b is characterised<br />
by bi-directional flows of the<br />
same products between different<br />
economies (Fig. 5). The preference<br />
for one product compared to another<br />
<strong>de</strong>pends on the ‘cost-benefit’ perception<br />
of the customer which can be<br />
translated into the ‘competitiveness<br />
factor’ for differentiated products of a<br />
producer [4]. This goes far beyond the<br />
Ricardian comparative cost advantage<br />
for heterogeneous but non-differentiated<br />
products. The higher the<br />
competitiveness factor, the higher is<br />
the market share of the producer. This<br />
can be seen as the mo<strong>de</strong>rn interpretation<br />
of the Heckscher-Ohlin factors<br />
proportion theory.<br />
The type 2 globalisation products<br />
<strong>de</strong>pend on the ‘intrinsic market fragmentation’<br />
of the business [4]. This<br />
market fragmentation is given by the<br />
characteristic of the product and the<br />
logistics and cost for it to be transported<br />
(Fig. 6). In<strong>de</strong>ed, combined with<br />
the fragmentation of the final <strong>de</strong>mand,<br />
this is an indicator for the necessary<br />
Fig. 5: Type 1b or globalisation of <strong>special</strong>ties<br />
ALUMINIUM · 1-2/2008<br />
polypolistic offer structure to reach<br />
the next transformation stage of the<br />
value-addition chain or to be distributed<br />
to the final customer. The types<br />
1a, 1b, and 2 are the natural globalisation<br />
types.<br />
Type 1c is based on the price differential<br />
of the same product between<br />
two economies, which we may call the<br />
‘propensity for globalisation’ [4]. The<br />
higher this difference is, the higher are<br />
the material flows of such products<br />
although – from the intrinsic nature<br />
of the business – this should result<br />
in type 2 globalisation as is typically<br />
the case for extrusions (Fig. 7). This<br />
globalisation lasts as long as the price<br />
difference exists, i. e. as long as the incentive<br />
is high enough. In particular,<br />
extrusions in North America are being<br />
confronted with the type 1c globalisation<br />
phenomenon from China [6].<br />
Type 3 globalisation is mo<strong>de</strong>lled<br />
by the ‘comparative skill of labour’,<br />
i. e. the level of skills available and<br />
the respective cost as well as the cost<br />
of transferring the service consi<strong>de</strong>red<br />
to a lower-cost economy (Fig. 8). This<br />
globalisation type too will last as long<br />
as the salary cost advantage persists.<br />
The intrinsic logic and mathematical<br />
mo<strong>de</strong>ls governing the triggering and<br />
evolution of each globalisation type<br />
are beyond the scope of this limited<br />
discussion and can be consulted in<br />
the appropriate literature [4].<br />
Applying these findings to the<br />
portfolio of different aluminium technologies<br />
shown in the matrix of Fig. 2<br />
we can assert the following: the bauxite,<br />
alumina, and primary aluminium<br />
businesses follow rather a material<br />
type 1a globalisation pattern, i. e. the<br />
growing <strong>de</strong>mand in emerging coun-<br />
ECONOMICS<br />
tries will boost the flow of raw materials<br />
from the sources to these new<br />
industrializing regions. The material<br />
flows will grow not only in volume<br />
terms; the interaction of the different<br />
economies will also increase and the<br />
centre of gravity will shift to these new<br />
emerging economic regions. Rolling,<br />
extrusions, castings, and forgings will<br />
rather follow a financial type 2 globalisation<br />
pattern, with companies building<br />
up a network of similar operations<br />
via FDI in accordance with a market<br />
coverage strategy. In<strong>de</strong>ed, Sapa and<br />
Hydro, but also Indalex limited to<br />
the North American region, are typical<br />
examples of extrusion industries<br />
that follow such a market coverage<br />
strategy, exploiting their know-how<br />
of manufacturing and to promote<br />
their extrusion business. The spin-off<br />
regarding the ex-Alcan rolling activities<br />
forming Novelis, as well as Aleris<br />
from Corus, are also good examples<br />
of how to create a technology-centred<br />
business mo<strong>de</strong>l focussed on the better<br />
servicing of market needs. Despite the<br />
fact that the casting and forging industries<br />
used to be dominated by familyowned,<br />
single plant companies, there<br />
too a tentative creation of networks<br />
can be observed. All these polypolistic<br />
businesses are characterized by an<br />
increased level of M&A or the set-up<br />
of new plants in emerging economic<br />
regions. On the other hand, type 2<br />
strategies can also be observed in type<br />
1a characterized markets, such as the<br />
merger of Rusal, Sual, and Glencore.<br />
But here there exists a big difference<br />
in the logic: whereas on the one hand<br />
in markets primarily characterized by<br />
type 2 globalisation the business itself<br />
is fragmented and remains regional,<br />
on the other hand when a secondary<br />
type 2 pattern overlies a type 1a<br />
pattern, the markets remain characterized<br />
by material flow from the<br />
countries of origin to the <strong>de</strong>stination<br />
countries all over the world. In fact,<br />
the first case is a ‘conditio sine qua<br />
non’ for growth in new geographic regions,<br />
while the second case provi<strong>de</strong>s<br />
the option to growth further when<br />
the present mines are reaching their<br />
exploitation limits. The ongoing concentration<br />
process of the aluminium<br />
primary industry is a typical example<br />
[3]. Building applications such �<br />
19
ECONOMICS<br />
Fig. 6: Type 2 or financial globalisation<br />
as window and faça<strong>de</strong> systems can be<br />
consi<strong>de</strong>red to belong to the type 1b<br />
globalisation pattern. In<strong>de</strong>ed, <strong>de</strong>spite<br />
the rather fragmented building industry,<br />
proprietary building systems from<br />
suppliers such as Schuco and similar<br />
ones are often sold worldwi<strong>de</strong> as the<br />
consequence of winning international<br />
contracts. Further, in our industry we<br />
also have examples of globalisation<br />
type 1c. In fact, for some years exports<br />
of extrusions from China to the<br />
United States have been increasing<br />
rapidly and attained a market share<br />
of an astonishing 9% at the end of<br />
2007 [6]. The price differences between<br />
imported and locally produced<br />
extrusions observed were up to 20%,<br />
showing a high propensity for globalisation<br />
which ma<strong>de</strong> it possible to ship<br />
standardized products even across<br />
long distances. Despite that, due to its<br />
fragmented characteristics the extrusion<br />
market follows naturally, if ever,<br />
a type 2 strategy. This transient type<br />
1c globalisation will last as long as the<br />
price difference is large enough [4].<br />
Generally, all these imperialistic<br />
expansion strategies are often <strong>de</strong>nounced<br />
by public opinion. But the<br />
natural types of globalisation (i. e. 1a,<br />
1b, 2) are not responsible for social<br />
consequences such as unemployment;<br />
the socio-political consequences<br />
are mainly caused by the transient<br />
types of globalisation (i. e. 1c and 3).<br />
That, however, is another story. The<br />
phenomenological mo<strong>de</strong>lling of economic<br />
globalisation presented here<br />
is further accompanied by a common<br />
<strong>de</strong>nominator for the intrinsic reason<br />
of macroeconomic globalisation evolution.<br />
This rationale behind it, which<br />
is groun<strong>de</strong>d on entropy-based inequality<br />
and <strong>de</strong>rived risk metric, leads<br />
to The Central Theorem of Globalisation<br />
an explanation of which would<br />
be far beyond the scope of the present<br />
paper [4].<br />
The peculiarity of the aluminium<br />
industry’s value-addition chain<br />
The aluminium industry has been<br />
mainly composed of fully vertically<br />
integrated concerns covering bauxite<br />
extraction, alumina refining, primary<br />
aluminium smelting, various semis<br />
production technologies, and sometimes<br />
going as far as the manufacture<br />
of fully-finished components for the<br />
automotive, aerospace or electrotechnical<br />
industries (Fig. 9). It is interesting<br />
to see the apparently neat division<br />
between the upstream operations<br />
(bauxite, alumina and primary) and<br />
the so-called downstream technologies<br />
(rolling, extrusion, casting, and<br />
forging). In<strong>de</strong>ed, primary aluminium<br />
production is a two-step casca<strong>de</strong>d<br />
process supplying the common basic<br />
Fig. 7: Type 1c or opportunistic cost globalisation<br />
raw material to all the other aluminium<br />
semis operations. The figure also<br />
shows the relative business typology<br />
and related globalisation type at each<br />
level of the value-addition chain. Accordingly,<br />
we cannot simply say that<br />
a general globalisation ten<strong>de</strong>ncy can<br />
be observed in the aluminium industry;<br />
it can also be asserted that it will<br />
perform differently along the ad<strong>de</strong>dvalue<br />
chain in accordance with the<br />
different logics, with different effects<br />
on the competitive system as well as<br />
the social system of employment.<br />
Moreover, there are evi<strong>de</strong>nt differences<br />
between the levels of the<br />
value-addition chain. Although the<br />
semis operations have the same globalisation<br />
type, we can assume that<br />
between the different semis operations<br />
there are no relevant synergies<br />
observable from a management point<br />
of view (except in contingent situations),<br />
and of course the alloys used<br />
are often quiet different, with separate<br />
recycling loops, and the products from<br />
different technologies are only partly,<br />
if ever, substitutable and therefore<br />
need different conceptual engineering<br />
<strong>de</strong>sign. The reason for backward<br />
integration is more related to having<br />
direct access to the aluminium metal,<br />
i.e. to securing the supply si<strong>de</strong>.<br />
So are fully integrated aluminium<br />
concerns a run-out mo<strong>de</strong>l? This <strong>de</strong>pends<br />
largely on the business mo<strong>de</strong>l<br />
adopted by the parent company and<br />
will be a key issue in examining the<br />
survival logic of today’s remaining aluminium<br />
companies. In general it can<br />
be said that it is difficult to dominate<br />
a business profitably beyond a certain<br />
well-<strong>de</strong>fined range of the whole<br />
value-addition chain. There are mar-<br />
20 ALUMINIUM · 1-2/2008
keting, technological and management reasons for this, going<br />
back to the concept of economies of scale. In<strong>de</strong>ed, there is<br />
no integrated company that fabricates a final product such<br />
as a car, which is fully backward integrated. Specifically,<br />
taking the example of the automotive industry, companies<br />
concentrate on core activities such as engine <strong>de</strong>velopment<br />
(and manufacturing) and e<strong>special</strong>ly the whole assembly operation<br />
of the car. This represents a very tiny range of the<br />
value-addition chain of automotive manufacturing. In<strong>de</strong>ed,<br />
today the ad<strong>de</strong>d value generated per hour is more important<br />
than the ad<strong>de</strong>d value generated per car, For brand marketing<br />
reasons it is important to be able to sell more cars with the<br />
same brand and increased prestige, as well as to increase the<br />
buying power for the components [7].<br />
An alternative to vertical integration could be to have a<br />
horizontal expansion of the same technology, such as rolling<br />
for Novelis and extrusions for Sapa, or at least similar ones<br />
that offer synergies from the technological point of view or<br />
for the same markets with different technologies in or<strong>de</strong>r<br />
to offer alternative solutions, such as Corus with steel and<br />
aluminium (which is no longer being pursued due to final<br />
concentration on the steel business). This can take place at<br />
every level of the value-addition chain, i. e. mining, or smelting,<br />
or rolling, or extrusion, or even casting (sand or diecasting,<br />
steel and aluminium). In general the following basic<br />
question has to be answered: is the core business content to<br />
sell products of a specific technology to all markets, or is the<br />
core business content to serve a specific market with different<br />
technologies? The first mo<strong>de</strong>l has more a capacity-filling<br />
logic and the second one more a product-solution approach.<br />
This distinction is more important than many people believe;<br />
there is nothing worse than believing that one is selling a<br />
product for a certain application market whereas in reality<br />
the <strong>de</strong>stination of the application market is irrelevant and<br />
the transaction object is rather a service with the un<strong>de</strong>rlying<br />
business following a technological capacity-filling logic<br />
irrelevant to the application. In fact, care must be taken not<br />
to follow the often undifferentiated preaching of “you have<br />
to become market-orientated” by generic consultants of the<br />
past, which was often un<strong>de</strong>rstood as application segmentation.<br />
It is necessary to un<strong>de</strong>rstand the intrinsic logic of<br />
each single business, to achieve not only undifferentiated<br />
customer orientation but even very differentiated customer<br />
<strong>de</strong>dication that fulfils their specific needs even in<strong>de</strong>- �<br />
Fig. 8: Type 3 or globalisation of human factor<br />
ALUMINIUM · 1-2/2008<br />
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21
ECONOMICS<br />
Fig. 9: The value-addition chain of the aluminium industry<br />
pen<strong>de</strong>ntly of the application [5]. The<br />
semis industry is characterised by B2B<br />
and not B2C marketing. Un<strong>de</strong>rstanding<br />
the intrinsic nature of the semis<br />
business will be the key to success in<br />
future competition. Of course, certain<br />
technologies are more appropriate for<br />
MNEs than for SMEs due to capital<br />
intensiveness. But everyone has the<br />
possibility to participate in the race<br />
for global dominance. It is evi<strong>de</strong>nt<br />
that the possibility to build-up a type<br />
2 globalisation strategy for a specific<br />
semis technology is very realistic, as<br />
the logic and examples show.<br />
These are the known facts – so<br />
what next? Taking into consi<strong>de</strong>ration<br />
these few thoughts, we can question<br />
the logical division marking the interface<br />
between upstream and downstream<br />
with the transfer product being<br />
the ingot (or rolling slab as well as<br />
extrusion billet). The risk of remaining<br />
short of metal supply is marginal<br />
for SMEs that carry out downstream<br />
operations, consi<strong>de</strong>ring their production<br />
capacities in relation to the total<br />
metal supply. For MNEs, long-term<br />
contracts with primary producers can<br />
bypass the issue of not having one’s<br />
own metal production. This is valid<br />
for all operations where pricing is<br />
generally based on tolling or similar<br />
margin calculations. Are there other<br />
interfaces? Yes, as also between alumina<br />
and primary metal. In<strong>de</strong>ed, the<br />
peculiarity of the electrolysis process<br />
that yields liquid primary aluminium<br />
is that it necessitates a continuous,<br />
uninterrupted process. The cells have<br />
to be constantly fed with alumina (and<br />
current) in or<strong>de</strong>r to avoid sealing. The<br />
liquid metal output of a smelter is constant<br />
and in case of low <strong>de</strong>mand, the<br />
production increases<br />
the nonsold<br />
ingot stock<br />
and the LME ingot<br />
price will go<br />
down because<br />
supply exceeds<br />
<strong>de</strong>mand. On the<br />
other hand, the<br />
bauxite and alumina<br />
production<br />
level, which can<br />
be controlled<br />
to some extent,<br />
can be adapted<br />
to <strong>de</strong>mand. The bottleneck will most<br />
probably be formed by the railway’s<br />
capacity to transport the bauxite.<br />
From that point of view it makes sense<br />
to combine bauxite and alumina production<br />
(including reflections about<br />
optimised sourcing of caustic soda)<br />
in or<strong>de</strong>r to reduce the transportation<br />
volume by half. It becomes evi<strong>de</strong>nt<br />
that primary aluminium production<br />
is a different business from mining<br />
although it belongs to the same globalisation<br />
type. For that reason we can<br />
assert that for the mining giant Rio<br />
Tinto to go into the primary aluminium<br />
business is already a downstream<br />
expansion into a new technology.<br />
Another interface exists between<br />
components manufacturing and the<br />
different semis-operations. To increase<br />
the supplied value-addition<br />
content of semis-products, semisplants<br />
try to perform additional mechanical<br />
operations as a service to<br />
their customers or even become involved<br />
in component <strong>de</strong>velopment<br />
[7]. The question is how far this<br />
should go. If the downstream activity<br />
comprises more than only finishing<br />
operations but rather the fabrication<br />
of ready-to-fit parts (even combined<br />
with engineering content), the business<br />
content might be quite different<br />
from pure semis production, with a<br />
production philosophy of one-piece<br />
flow in one case and batch production<br />
in the other case. The <strong>de</strong>cision<br />
to go along that road has to be well<br />
evaluated.<br />
It becomes evi<strong>de</strong>nt, that not only<br />
the globalisation pattern may be different<br />
for each step of the value-addition<br />
chain, but also that the intrinsic<br />
issues are specific to each step. In the<br />
next section we will see that also the<br />
CSFs (Critical Success Factors) are<br />
specific to each step of the value-addition<br />
chain.<br />
To be continued in ALUMINIUM<br />
3/2008<br />
References<br />
1) Rio Tinto to buy Alcan, ALUMINIUM<br />
7-8/2007, Giesel Verlag.<br />
2) Pawlek R., The Rio Tinto Alcan <strong>de</strong>al<br />
– marking the dawn of a new era for metals,<br />
ALUMINIUM 9/2007, Giesel Verlag.<br />
3) Conserva, M.: Global Market Trends<br />
of <strong>Alu</strong>minium and <strong>Alu</strong>minium Products,<br />
Proceedings of the 6 th World Congress<br />
ALUMINIUM 2000, Florence Italy, March<br />
13-17, 2007, Interall publications.<br />
4) Rüttimann, B.: Mo<strong>de</strong>lling Economic<br />
Globalisation – A Post-Neoclassic View<br />
on Foreign Tra<strong>de</strong> and Competition, Verlagshaus<br />
Monsenstein und Vannerdat,<br />
Edition MV-Wissenschaft, Münster, 2007;<br />
ISBN 978-3-86582-447-9.<br />
5) Rüttimann, B.: Strategy and tactics in<br />
the aluminium semi-finished products industry,<br />
ALUMINIUM 78 (2002) 1/2 and 4.<br />
6) Rüttimann, B.: The Globalisation Trap<br />
of the <strong>Alu</strong>minum Extrusion Industry, Paper<br />
to be presented at the 9th International<br />
Extrusion Technology Congress ET08,<br />
May 13-16, 2008 Orlando FL USA.<br />
7) Hagen, H.; Rüttimann, B.: The automotive<br />
market – the new challenge for the<br />
aluminium industry, ALUMINIUM 80<br />
(2004) 3 and 4.<br />
Author<br />
Dr.-Ing. Bruno G. Rüttimann, MBA, graduated<br />
from Milan Polytechnic and Bocconi<br />
University of Economics in Milan. Since<br />
2003 he has been in charge of continuous<br />
improvement within Alcan Engineered<br />
Products. As Master Black Belt he supports<br />
the introduction of the Lean Six Sigma<br />
culture to increase the competitiveness<br />
of the plants.<br />
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22 ALUMINIUM · 1-2/2008
Marubeni predicts aluminium surplus in 2008<br />
Japanese trading house Marubeni expects<br />
a global aluminium surplus of<br />
543,000 tonnes in 2008 as new production<br />
comes on stream, but predicted<br />
a tightening in 2009 on increased<br />
Chinese consumption. Global aluminium<br />
consumption will grow by 9.5% to<br />
41.26m t in 2008 and a further 5.6% to<br />
43.56m t in 2009. Production in 2008<br />
is expected to grow 10% to 41.80m<br />
t as new capacity comes on stream.<br />
Rio’s outlook for metals and minerals<br />
For aluminium Rio makes the<br />
following forecast: <strong>Alu</strong>minium<br />
consumption has grown the fastest<br />
of all non-ferrous metals over<br />
the last five years and is forecast<br />
to grow rapidly over the next 20<br />
years: There has been enormous<br />
recent growth in Chinese consumption<br />
and production, but<br />
aluminium has benefited from<br />
increasing use in many other regions<br />
including the OECD.<br />
Constraints on China’s domestic<br />
bauxite production suggest that the<br />
country’s massive investment in primary<br />
aluminium will still relay largely<br />
on imported bauxite. This, combined<br />
with China’s high power costs, means<br />
ALUMINIUM · 1-2/2008<br />
The surplus of supply over <strong>de</strong>mand in<br />
the CIS region may rise from 3.47m t in<br />
2007 to 3.86m t in 2008 as output rises<br />
by 10.6% to 5.01m t. The supply-and<strong>de</strong>mand<br />
balance in China, however,<br />
is forecast to be perfectly matched in<br />
2008 at around 15m t. However, an<br />
8% increase in Chinese consumption<br />
to 16.2m t in 2009 is likely to lead to<br />
a 100,000 t shortfall in supply. Global<br />
consumption in 2009 is forecast<br />
that Chinese aluminium capacity will<br />
continue to be high-cost in a global<br />
comparison. Additionally, Chinese<br />
production will eventually suffer<br />
from a stronger currency as the RMB<br />
edges toward fair exchange rate. The<br />
implied increase in the marginal cost<br />
of production for alumina and aluminium<br />
mean, that their prices are<br />
unlikely to revert to the lower levels<br />
implied by historical trends.<br />
Spot aluminium prices have mo<strong>de</strong>rated<br />
by about 10% since the middle<br />
of 2007 and are currently moving in<br />
the range of US$2450-2550 per tonne,<br />
which still covers production costs at<br />
the highest cost smelters. Forward<br />
prices have increased in relation to<br />
spot prices reflecting a market expec-<br />
ECONOMICS<br />
to reach 43.56m t, and production<br />
43.77m t, leading to a global oversupply<br />
of around 210,000 t.<br />
The trading house is also forecasting<br />
prices to continue their upward<br />
trend, averaging between US$2,300<br />
and US$3,000 per tonne in 2008, and<br />
between US$2,500 and US$3,500 per<br />
tonne in 2009.<br />
paw<br />
tation that smelters with high marginal<br />
costs will still be nee<strong>de</strong>d to meet<br />
<strong>de</strong>mand over the medium term.<br />
<strong>Alu</strong>minium is forecast to continue<br />
to enjoy rapid growth over the next<br />
two <strong>de</strong>ca<strong>de</strong>s. CRU projects consumption<br />
to grow by more than 140% over<br />
the period to 2030. One reason for the<br />
recent growth is that China’s economic<br />
<strong>de</strong>velopment is highly aluminium<br />
intensive. But at the same time aluminium<br />
has gained worldwi<strong>de</strong> in intensity<br />
of use and has partly replaced<br />
other materials across a wi<strong>de</strong> range of<br />
applications.<br />
The strong and sustained growth<br />
in aluminium <strong>de</strong>mand is starting to<br />
stretch the resource base that has so<br />
far allowed unlimited growth of �<br />
23
ECONOMICS<br />
the aluminium industry: large-scale,<br />
good-quality bauxite <strong>de</strong>posits and regions<br />
of relatively cheap energy.<br />
In the case of bauxite the escalation<br />
in <strong>de</strong>mand for aluminium is being<br />
met increasingly from high-cost<br />
and small-scale bauxite <strong>de</strong>posits in<br />
China, and by opportunistic mining<br />
operations in Indonesia. Such sources<br />
of supply are unlikely to provi<strong>de</strong> a<br />
long-term solution for the industry’s<br />
rapidly growing bauxite needs and<br />
have already led to stronger prices<br />
for tra<strong>de</strong>d ore. Bauxite supply therefore<br />
requires significant investment in<br />
large scale mines if the industry is to<br />
meet <strong>de</strong>mand projections.<br />
Meanwhile, high energy prices,<br />
combined with a greater integration<br />
between regional energy markets<br />
through the <strong>de</strong>velopment of LNG and<br />
gas-to-liquids projects, could increase<br />
the costs of power available to greenfield<br />
smelters around the world. Together<br />
with a likely trend towards the<br />
introduction of pricing mechanisms<br />
or tax regimes for carbon emissions,<br />
sustainable isolated hydropower<br />
sources have become more valuable.<br />
This in turn may increase the value of<br />
In December 2007 China has announced<br />
gui<strong>de</strong>lines for those who<br />
wish to enter the domestic aluminium<br />
industry, according to the<br />
National <strong>de</strong>velopment and Reform<br />
Commission.<br />
All new <strong>de</strong>velopment projects in the<br />
aluminium sector, including mining,<br />
alumina refining, ingot melting and<br />
recycling as well as fabrication plants,<br />
must abi<strong>de</strong> by all requirements of the<br />
various state <strong>de</strong>partments. These inclu<strong>de</strong><br />
basic requirements for proper<br />
land use, safety and environmental<br />
regulations.<br />
Un<strong>de</strong>r the gui<strong>de</strong>lines, smelting<br />
facilities cannot be built within one<br />
kilometre of protected regions, such<br />
as water preservation areas, protected<br />
farming areas, protected natural reservations,<br />
famous scenic attractions,<br />
existing aluminium capacity linked to<br />
such power sources.<br />
In the context of growing <strong>de</strong>mand<br />
and constraining supply, the longterm<br />
price <strong>de</strong>velopment for aluminium<br />
will much <strong>de</strong>pend on the evolution<br />
of costs. Turning first to alumina,<br />
refineries relying on imported bauxite<br />
supplies, such as those in Europe and<br />
the US Gulf coast, have traditionally<br />
occupied the top-end of the alumina<br />
cost curve. High energy prices and<br />
rising <strong>de</strong>livered bauxite costs have<br />
aggravated the competitive disadvantage<br />
of these refineries during the<br />
past five years. The Chinese industry<br />
is currently drawing on its capital cost<br />
advantage to add significant non-integrated<br />
alumina capacity, but these<br />
refineries are rapidly joining US and<br />
European alumina refineries toward<br />
the top of the cost curve. The resulting<br />
increase in the marginal cost of production<br />
means that alumina prices are<br />
unlikely to revert to the lower levels<br />
implied by historical trends, even if<br />
some higher cost integrated capacity<br />
is eventually replaced by lower cost<br />
production.<br />
In the case of aluminium, as with<br />
major cities and their nearby surrounding<br />
countrysi<strong>de</strong>, as well as hospitals,<br />
food, medical and electronic<br />
business.<br />
New bauxite mining projects with<br />
an investment of more than Yuan<br />
500m (US$67.3m) will require approval<br />
from the investment management<br />
division of China’s State Council.<br />
Those with a smaller investment will<br />
require approval from the investment<br />
management divisions of their respective<br />
provincial governments. All mining<br />
projects seeking approval must<br />
have at least a 300,000 tpy capacity<br />
and a minimum life span of 15 years.<br />
All new alumina projects must be<br />
approved by the investment management<br />
division of the State Council.<br />
Those using domestic bauxite as<br />
feed must have an initial capacity of<br />
at least 800,000 tpy, and a minimum<br />
alumina, new Chinese smelters are<br />
fundamentally changing the shape<br />
of the industry cost curve. The rapid<br />
increase in Chinese smelting capacity<br />
since the start of this <strong>de</strong>ca<strong>de</strong> reflects<br />
the relatively low entry barriers in<br />
building smelters, due to China’s low<br />
capital costs and short build times.<br />
However, this new capacity has come<br />
in at the top-end of the operating cost<br />
curve, mainly reflecting relatively<br />
high power costs. Consequently, the<br />
industry aluminium cost curve has<br />
shifted up since 2003 and become<br />
steeper. This has provi<strong>de</strong>d a new significantly<br />
higher base for prices.<br />
A key point to note is that the<br />
gradual appreciation of the Chinese<br />
currency should also translate into<br />
higher US dollar production costs for<br />
Chinese smelters – all other things<br />
being equal. With Chinese smelters<br />
predominantly in the third and<br />
fourth quartiles, the top end of the<br />
curve would shift up in such a scenario<br />
creating an even higher basis for<br />
aluminium prices and higher margins<br />
for smelters elsewhere in the lower<br />
cost quartiles.<br />
R. P. Pawlek, Sierre<br />
China sets gui<strong>de</strong>lines<br />
for domestic aluminium and alumina projects<br />
lifespan of 30 years; those using imported<br />
bauxite as feed must have an<br />
initial capacity of at least 600,000 tpy,<br />
and reliable feed supply such as longterm<br />
contracts for at least five years<br />
of <strong>de</strong>livery.<br />
New ingot smelting projects will<br />
also require approval from the State<br />
Council’s investment management<br />
division. In the near term the Council<br />
will consi<strong>de</strong>r only upgrading projects<br />
to suit environmental requirements<br />
and to replace outdated machinery.<br />
These projects also require guaranteed<br />
alumina feed supply, sufficient<br />
power supply, and efficient transport<br />
conditions.<br />
New secondary and recycling aluminium<br />
projects must have at least a<br />
capacity of 50,000 tpy; existing plants<br />
should have at last a capacity of 20,000<br />
tpy, and expansion projects must have<br />
24 ALUMINIUM · 1-2/2008
at least a capacity of 30,000 tpy.<br />
In the aluminium fabricating sector,<br />
new projects have to focus on<br />
sheet, strip, foil and extrusion. Projects<br />
ECCA<br />
Production of stripcoated<br />
aluminium<br />
gains new momentum<br />
At its 41 st Autumn Conference<br />
held between 18 and 20 November<br />
2007 in Brussels the European<br />
Coil Coating Association<br />
(ECCA) reported sustained growth<br />
in the production of strip-coated<br />
aluminium.<br />
Whereas the annual growth rates of<br />
strip-coated steel have averaged ten<br />
percent over a number of years, since<br />
2000 aluminium had been showing<br />
a downward ten<strong>de</strong>ncy which was<br />
not reversed until 2006, with a rise<br />
of eight percent compared with the<br />
year before. Happily, the strip coater<br />
members of the ECCA were able to<br />
announce a new production increase<br />
for aluminium strip in the first half of<br />
2007, by as much as 22 percent compared<br />
with the same period a year<br />
earlier. That growth can mainly be attributed<br />
to extensive <strong>de</strong>liveries<br />
for the building sector, in<br />
which strip-coated aluminium<br />
is used for example to<br />
produce wall, <strong>de</strong>ck and roof<br />
sections and for composite<br />
panels, doors and gates.<br />
The conference motto<br />
was “European regulations:<br />
threat or opportunities for<br />
coil coating?” In that connection<br />
many lectures <strong>de</strong>alt with<br />
the consequences of current<br />
European legislation for both<br />
strip coaters and the users of<br />
strip-coated products. One<br />
theme was the influence of<br />
European legislation on the<br />
building sector, which is<br />
by far the largest individual<br />
market for coated strip of<br />
both aluminium and steel.<br />
Besi<strong>de</strong>s building regulations,<br />
the European gui<strong>de</strong>lines<br />
ALUMINIUM · 1-2/2008<br />
with combined capacity must produce<br />
at least 100,000 tpy. Approval<br />
for projects producing a single product<br />
will <strong>de</strong>pend on the product type<br />
Auf ihrer 41. Herbstkonferenz<br />
vom 18. bis 20. November 2007 in<br />
Brüssel berichtete die European<br />
Coil Coating Association (ECCA)<br />
über ein anhalten<strong>de</strong>s Produktionswachstums<br />
von bandbeschichtetem<br />
<strong>Alu</strong>minium.<br />
Während die jährlichen Zuwachsraten<br />
von bandbeschichtetem Stahl seit<br />
vielen Jahren durchschnittlich zehn<br />
Prozent betragen, war bei <strong>Alu</strong>minium<br />
seit 2000 eine rückläufige Ten<strong>de</strong>nz zu<br />
verzeichnen, die sich erst 2006 mit<br />
einer Steigerung von acht Prozent<br />
gegenüber <strong>de</strong>m Vorjahr umkehrte.<br />
Erfreulich, dass die in <strong>de</strong>r ECCA<br />
zusammengeschlossenen Bandbeschichter<br />
für das erste Halbjahr 2007<br />
einen erneuten Produktionsanstieg<br />
bei <strong>Alu</strong>minium mel<strong>de</strong>n konnten,<br />
und zwar um 22 Prozent gegenü-<br />
ECONOMICS<br />
– sheet/strip must have at least 50,000<br />
tpy, foil a minimum of 30,000 tpy and<br />
extrusion of aluminium 50,000 tpy.<br />
R. P. Pawlek, Sierre<br />
ECCA<br />
Produktion von beschichtetem<br />
<strong>Alu</strong>miniumband legt erneut zu<br />
Bandbeschichtete <strong>Alu</strong>paneele an <strong>de</strong>r Überdachung <strong>de</strong>s<br />
Eingangsbereichs Bahnhof Potsdam<br />
Strip-coated aluminium for the roofing of the entrance<br />
area at the train station in Potsdam near Berlin<br />
ber <strong>de</strong>m Vergleichszeitraum 2006.<br />
Dieses Wachstum ist in erster Linie<br />
auf umfangreiche Lieferungen für<br />
<strong>de</strong>n Bausektor zurückzuführen, wo<br />
bandbeschichtetes <strong>Alu</strong>minium z. B.<br />
für Wand-, Decken- und Dachprofile<br />
sowie für Verbundplatten, Türen und<br />
Tore eingesetzt wird.<br />
Die Konferenz stand unter <strong>de</strong>m<br />
Motto „European regulations,<br />
threat or opportunities for coil coating“.<br />
In diesem Zusammenhang wur<strong>de</strong><br />
in mehreren Vorträgen aufgezeigt,<br />
welche Konsequenzen sich aus <strong>de</strong>r<br />
aktuellen europäischen Gesetzgebung<br />
sowohl für die Bandbeschichter als<br />
auch für die Anwen<strong>de</strong>r bandbeschichteter<br />
Erzeugnisse ergeben. Ein Thema<br />
war <strong>de</strong>r Einfluss <strong>de</strong>r Europäischen<br />
Gesetzgebung auf <strong>de</strong>n Bausektor, <strong>de</strong>r<br />
sowohl für beschichtete <strong>Alu</strong>miniumwie<br />
für Stahlbän<strong>de</strong>r <strong>de</strong>r mit Abstand<br />
größte Einzelmarkt ist. Neben Regeln<br />
für die Bauausführung sind vor allem<br />
die europäischen Energie- und Emissionsschutzrichtlinien<br />
von Be<strong>de</strong>utung.<br />
Gera<strong>de</strong> hier ergeben sich vielfältige<br />
Ansatzpunkte, die Vorteile von beschichteten<br />
Substraten als verkaufsför<strong>de</strong>rn<strong>de</strong><br />
Eigenschaften zu nutzen.<br />
Ein weiteres Thema waren die<br />
Auswirkungen <strong>de</strong>r am 1. Juni 2007 in<br />
Kraft getretenen neuen EU-Gesetzgebung<br />
für Chemikalien – REACH<br />
– auf die weltweiten Lieferketten. Da<br />
die meisten <strong>de</strong>r wichtigen Bestimmungen<br />
am 1. Juni 2008 wirksam<br />
wer<strong>de</strong>n, stellt sich für je<strong>de</strong>n Hersteller<br />
die Frage, wie er seine nachgelagerten<br />
Anwen<strong>de</strong>r unterstützen<br />
kann. Das Leitprinzip von REACH<br />
– „Ohne Daten kein Markt“ – be<strong>de</strong>utet,<br />
dass alle europäischen Hersteller<br />
chemischer Stoffe ihre Produkte nur<br />
nach entsprechen<strong>de</strong>r Registrierung<br />
weiterhin anbieten dürfen.<br />
� �<br />
Photos: Alcan Singen<br />
25
WIRTSCHAFT<br />
Strenger wer<strong>de</strong>n<strong>de</strong> Auflagen für <strong>de</strong>n<br />
Umweltschutz stellen sowohl für die<br />
Hersteller, als auch für die Betreiber<br />
von Bandbeschichtungslinien eine<br />
große Herausfor<strong>de</strong>rung im Hinblick<br />
auf die Anpassung <strong>de</strong>r traditionell<br />
auf <strong>de</strong>r Verwendung von Chromat<br />
(Cr6 + ) beruhen<strong>de</strong>n Vorbehandlung<br />
und Neutralisierung dar. Die neuen<br />
EU-Bestimmungen schränken die<br />
Verwendung von Cr6 + für Automobil-<br />
(EU-Richtlinie EoVL) sowie Elektro-<br />
und Elektronikanwendungen (EU-<br />
Richtlinie RoHS) stark ein.<br />
Neben <strong>de</strong>m Einsatz <strong>de</strong>s durchaus<br />
umweltverträglichen dreiwertigen<br />
Chrom (Cr3 + ) begünstigte die Gesetzgebung<br />
die Entwicklung chromatfreier<br />
Ersatzlösungen. Einige Beispiele wur<strong>de</strong>n<br />
in Brüssel vorgestellt: Als Ersatz<br />
für chromhaltige Korrosionsschutzmittel<br />
zur Grundierung von <strong>Alu</strong>minium-<br />
und Stahlbän<strong>de</strong>rn eignen sich<br />
z. B. silikatische Pigmente mit Ionenaustausch.<br />
Bereits Mitte <strong>de</strong>r 1980er<br />
Jahre wur<strong>de</strong>n Pigmente auf Basis von<br />
Silikatprodukten mit Ionenaustausch<br />
als ungiftige und umweltverträgliche<br />
Alternative für die bislang bekannten<br />
Rostschutz-Pigmenttechniken auf<br />
<strong>de</strong>n Markt gebracht. Inzwischen<br />
haben sich diese Produkte als eine<br />
viel versprechen<strong>de</strong> Ersatzlösung für<br />
Chromate durchgesetzt und erlauben<br />
es <strong>de</strong>r Bandbeschichtungsindustrie,<br />
Grundierungen entsprechend <strong>de</strong>n<br />
angekündigten neuen europäischen<br />
Bestimmungen herzustellen.<br />
Als ein weiteres Beispiel für eine<br />
kostengünstige und qualitativ hochwertige<br />
Alternative zur chemischen<br />
Reinigung von Bän<strong>de</strong>rn wur<strong>de</strong> <strong>de</strong>r<br />
Einsatz von „Openair“-Plasma vorgetragen.<br />
Im Gegensatz zu <strong>de</strong>r bisher üblichen<br />
Wasser/Tensid-Reinigung <strong>de</strong>r<br />
Bän<strong>de</strong>r vor <strong>de</strong>m Auftrag einer Korrosionsschutzschicht<br />
han<strong>de</strong>lt es sich<br />
hier um einen umweltfreundlichen<br />
Trockenreinigungsprozess, <strong>de</strong>r die<br />
Energie von atmosphärischem Plasma<br />
nutzt. Damit können auch dünne<br />
Schichten von Schmiermitteln aus<br />
<strong>de</strong>m Walzprozess mit hoher Effizienz<br />
entfernt wer<strong>de</strong>n.<br />
Unter <strong>de</strong>m Motto „10 years into<br />
future“ fin<strong>de</strong>t die nächste ECCA-<br />
Konferenz vom 18. bis 21. Mai 2008<br />
in Malaga, Spanien, statt.<br />
B. Rieth, Meerbusch<br />
on energy and emission protection<br />
are of importance. It is precisely here<br />
that there are many ways of using the<br />
advantages of coated substrates as<br />
sales-promoting properties.<br />
Another theme was the effects on<br />
the worldwi<strong>de</strong> supply chain, of the<br />
new EU legislation on chemicals,<br />
REACH, that entered into force on 1<br />
June 2007. Since most of the important<br />
provisions take effect from 1 June<br />
2008, every manufacturer is faced by<br />
the question of how best to support<br />
his future users. The guiding principle<br />
of REACH – ‘No market without data’<br />
– signifies that all European manufacturers<br />
of chemicals may only continue<br />
offering their products after appropriate<br />
registration.<br />
Stricter environmental protection<br />
impositions present a great challenge<br />
for both manufacturers and operators<br />
of strip-coating lines as regards<br />
the adaptation of traditional pretreatments<br />
that rely on chromate (Cr6 + )<br />
and its neutralisation. The new EU<br />
provisions greatly restrict the use of<br />
Cr6 + for automobile (EU-Gui<strong>de</strong>line<br />
EoVL) and electric and electronic applications<br />
(EU-Gui<strong>de</strong>line RoHS).<br />
Besi<strong>de</strong>s the use of the entirely<br />
environmentally unobjectionable<br />
trivalent chromium (Cr3 + ), the legislation<br />
also encourages the <strong>de</strong>velopment<br />
of chromium-free alternative<br />
solutions. Some examples were proposed<br />
in Brussels: as a replacement<br />
for chromium-containing corrosion<br />
protection media for the priming of<br />
aluminium and steel strips, for example<br />
silicate pigments with ion exchange<br />
are suitable. As long ago as the<br />
mid-1980s pigments based on silicate<br />
products with ion exchange were already<br />
brought onto the market as new,<br />
non-toxic and environmentally unobjectionable<br />
alternatives for the previously<br />
known rust protection pigment<br />
techniques. Now, more than 20 years<br />
later, these products have emerged as<br />
a promising replacement solution for<br />
chromates and are enabling the stripcoating<br />
industry to produce primers<br />
that comply with the announced new<br />
European provisions.<br />
As a further example of an inexpensive<br />
and high-gra<strong>de</strong> alternative<br />
to the chemical cleaning of strips,<br />
the use of ‘Openair’ plasma has been<br />
proposed. In contrast to the previously<br />
usual water/surfactant cleaning<br />
<strong>Alu</strong>minium Centrum, Houten, Nie<strong>de</strong>rlan<strong>de</strong>, mit bandbeschichteter Fassa<strong>de</strong><br />
<strong>Alu</strong>minium Centrum, Houten, The Netherlands, with strip-coated faça<strong>de</strong><br />
of strips before the application of a<br />
corrosion protection layer, this is an<br />
environmentally friendly, dry cleaning<br />
process which utilises the energy<br />
of atmospheric plasma and enables<br />
even thin lubricant films from the rolling<br />
process to be removed with high<br />
efficiency.<br />
The next ECCA Conference, run<br />
un<strong>de</strong>r the motto “10 years into the future”,<br />
will take place between 18 and<br />
21 May 2008 in Malaga, Spain.<br />
B. Rieth, Meerbusch<br />
26 ALUMINIUM · 1-2/2008
Otto Rudolf Fuchs begeht 80. Geburtstag<br />
Am 14. Januar dieses Jahres feierte<br />
Otto Rudolf Fuchs, eine <strong>de</strong>r<br />
herausragen<strong>de</strong>n Unternehmerpersönlichkeiten<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
in Deutschland, seinen<br />
80. Geburtstag.<br />
Otto R. Fuchs kann auf ein beeindrucken<strong>de</strong>s<br />
Lebenswerk blicken, <strong>de</strong>nn<br />
die Otto Fuchs-Gruppe gehört mit<br />
einem Umsatz von 2,2 Mrd. Euro zu<br />
<strong>de</strong>n größten Mittelständlern Deutschlands.<br />
Nach wie vor ein Familienunternehmen<br />
ist <strong>de</strong>r Unternehmensverbund<br />
heute mit <strong>de</strong>r Herstellung von<br />
Hightech-Produkten für die Luft- und<br />
Raumfahrtindustrie sowie für die Automobil-<br />
und Bauindustrie breit aufgestellt<br />
und in zukunftsträchtigen expandieren<strong>de</strong>n<br />
Märkten vertreten.<br />
Geboren wur<strong>de</strong> Otto R. Fuchs am<br />
14. Januar 1928 im sauerländischen<br />
Meinerzhagen als Sohn von Hans Joachim<br />
Fuchs, <strong>de</strong>m geschäftsführen<strong>de</strong>n<br />
Gesellschafter <strong>de</strong>r Firma Otto Fuchs.<br />
Nach <strong>de</strong>m Studium <strong>de</strong>s Maschinenbaus<br />
und Berufspraktikum in <strong>de</strong>n USA<br />
tritt Otto R. Fuchs 1954 in <strong>de</strong>n väterlichen<br />
Betrieb in Meinerzhagen ein,<br />
wo <strong>de</strong>r zunächst die Abteilung Druck-<br />
und Spritzguss (sog. Spritzerei) leitet.<br />
1956 übernimmt er die Leitung <strong>de</strong>s<br />
Zweigwerks Dülken, das in <strong>de</strong>n sieben<br />
Jahren unter seiner Führung einen beachtlichen<br />
Aufschwung erlebt.<br />
1963 tritt Otto R. Fuchs in die Geschäftsführung<br />
<strong>de</strong>s Familienbetriebes<br />
ein und wird als weiterer Kommanditist<br />
<strong>de</strong>r Gesellschaft aufgenommen. Es<br />
beginnt <strong>de</strong>r Ausbau <strong>de</strong>s Meinerzhagener<br />
Unternehmens zu einem international<br />
operieren<strong>de</strong>n Konzern.<br />
Ein Jahr später erwirbt Otto Fuchs<br />
die Firma Heinz Schürmann & Co.<br />
aus Bielefeld: einen kleinen Betrieb<br />
zur Fertigung von Schaufenstern aus<br />
<strong>Alu</strong>miniumprofilen. Heute ist die<br />
Schüco International KG weltweit<br />
vertreten und Marktführer hochwer-<br />
ALUMINIUM · 1-2/2008<br />
Foto: Otto Fuchs KG<br />
tiger Systeme: u. a. für Fenster, Türen,<br />
Fassa<strong>de</strong>n, Wintergärten, Sicherheitsbauteile<br />
und Solaranlagen.<br />
1964 geht im Meinerzhagener<br />
Werk die 30.000-Tonnen-Schmie<strong>de</strong>presse<br />
in Betrieb, eine <strong>de</strong>r weltweit<br />
größten privat finanzierten Schmie<strong>de</strong>pressen.<br />
1966 steigt Otto Fuchs<br />
mit <strong>de</strong>m legendären Porsche-Flügelrad<br />
in die Großserienfertigung für geschmie<strong>de</strong>te<br />
<strong>Alu</strong>miniumrä<strong>de</strong>r ein.<br />
Otto Rudolf Fuchs<br />
Otto R. Fuchs übernimmt 1974 die<br />
persönliche Haftung und damit die<br />
Leitung <strong>de</strong>s Konzerns, <strong>de</strong>r 1979 mit<br />
seiner Initiative um eine weitere<br />
Tochtergesellschaft, die Weber Metals<br />
Inc., Los Angeles, USA, erweitert<br />
und zu einer <strong>de</strong>r führen<strong>de</strong>n <strong>Alu</strong>miniumschmie<strong>de</strong>n<br />
von Gesenk- und Freiformschmie<strong>de</strong>teilen<br />
für die Luftfahrt<br />
ausgebaut wird.<br />
Nach <strong>de</strong>m Tod <strong>de</strong>s Vaters im Jahre<br />
1992 erfolgt eine Neuordnung <strong>de</strong>r Beteiligungen<br />
an <strong>de</strong>r Gesellschaft. Otto<br />
R. Fuchs und seine Halbschwester<br />
Christiane Fuchs übernehmen je 50<br />
Prozent <strong>de</strong>r Gesellschaftsanteile, die<br />
übrigen Gesellschafter schei<strong>de</strong>n aus<br />
<strong>de</strong>m Unternehmen aus. 1993 vollen<strong>de</strong>t<br />
Otto R. Fuchs sein 65. Lebensjahr<br />
und been<strong>de</strong>t die Geschäftsführung als<br />
persönlich haften<strong>de</strong>r Gesellschafter,<br />
begleitet jedoch weiterhin aktiv das<br />
Unternehmen als Kommanditist.<br />
WIRTSCHAFT<br />
Nach Überwindung <strong>de</strong>r konjunkturellen<br />
Rezession Anfang <strong>de</strong>r 1990er<br />
Jahre nimmt das Unternehmen wie<strong>de</strong>r<br />
Fahrt auf. Mit <strong>de</strong>m größten amerikanischen<br />
Hersteller von gegossenen<br />
<strong>Alu</strong>miniumrä<strong>de</strong>rn grün<strong>de</strong>t Otto<br />
Fuchs in Ungarn ein Joint Venture<br />
zur Herstellung von gegossenen und<br />
geschmie<strong>de</strong>ten Rä<strong>de</strong>rn für die europäische<br />
Automobilindustrie. Der Betrieb<br />
wird 1997 aufgenommen.<br />
Ein weiteres Joint Ventures folgt<br />
2006 in Südafrika. Hier produziert<br />
Otto Fuchs in East London an <strong>de</strong>r südafrikanischen<br />
Ostküste in Großserie<br />
<strong>Alu</strong>minium-Querlenker zusätzlich zu<br />
<strong>de</strong>r Meinerzhagener Fertigung für einen<br />
ihrer größten Kun<strong>de</strong>n: die Daimler<br />
AG. 2007 wird im Meinerzhagener<br />
Werk eine <strong>de</strong>r mo<strong>de</strong>rnsten Ringwalzanlagen<br />
in Betrieb genommen. Mit<br />
dieser Investition wird Otto Fuchs<br />
zu einem be<strong>de</strong>uten<strong>de</strong>n Anbieter von<br />
Triebwerksringen und -scheiben.<br />
Für seine persönliche und unternehmerische<br />
Lebensleistung und sein<br />
Engagement für das wirtschaftliche<br />
und gesellschaftliche Wohl <strong>de</strong>r Stadt<br />
Meinerzhagen und seiner Bürger wird<br />
Otto R. Fuchs im Jahre 2003 das Ehrenbürgerrecht<br />
und <strong>de</strong>r Ehrenring<br />
<strong>de</strong>r Stadt Meinerzhagen verliehen.<br />
Zur För<strong>de</strong>rung <strong>de</strong>s kulturellen Lebens<br />
in seiner Heimatstadt Meinerzhagen<br />
grün<strong>de</strong>t Otto R. Fuchs eine Stiftung,<br />
die er mit einer Spen<strong>de</strong> in Höhe von<br />
einer Million Euro ausstattet.<br />
Verwurzelt in seiner Heimat Meinerzhagen<br />
im südlichen Westfalen, ist<br />
Otto R. Fuchs nicht nur „aktiver“ Gesellschafter<br />
seines Unternehmens,<br />
son<strong>de</strong>rn in seiner Freizeit unter an<strong>de</strong>rem<br />
lei<strong>de</strong>nschaftlicher Pfer<strong>de</strong>züchter.<br />
Aus seiner Zucht von Hannoveranern<br />
hat so manches Nachwuchspferd<br />
große Berühmtheit erlangt.<br />
Die Redaktion ALUMINIUM gratuliert<br />
nachträglich zum Geburtstag.<br />
�<br />
Bezugsquellen sinnvoll nutzen<br />
Auf <strong>de</strong>n Seiten 112 bis 128 präsentieren führen<strong>de</strong> Ausrüstungspartner<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie ihr Angebot. Nutzen Sie diese wertvollen Informationen!<br />
27
WIRTSCHAFT<br />
EEG-Ausgleichsregelung für stromintensive Betriebe<br />
Ersparnisse von mehr als einer halben Milliar<strong>de</strong> Euro<br />
Unternehmen, die aus produktionstechnischen<br />
Grün<strong>de</strong>n beson<strong>de</strong>rs<br />
viel Strom benötigen, wer<strong>de</strong>n<br />
laut Bun<strong>de</strong>sumweltministerium<br />
(BMU) dieses Jahr erneut bei<br />
ihren Stromkosten entlastet, darunter<br />
378 Firmen <strong>de</strong>s produzieren<strong>de</strong>n<br />
Gewerbes. Das Gesamtvolumen<br />
<strong>de</strong>r Entlastung liegt 2008<br />
laut BMU in einer Größenordnung<br />
von 650 Mio. Euro. Von <strong>de</strong>r Ausgleichsregelung<br />
<strong>de</strong>s Erneuerbare-<br />
Energien-Gesetzes (EEG) profitieren<br />
rund zehn Prozent mehr<br />
Unternehmen als im Vorjahr.<br />
Hauptgrund hierfür ist, dass angesichts<br />
steigen<strong>de</strong>r Strompreise eine<br />
wachsen<strong>de</strong> Zahl von Unternehmen<br />
die Eingangskriterien <strong>de</strong>r Regelung<br />
erfüllen.<br />
Nach <strong>de</strong>m EEG wer<strong>de</strong>n die Kosten<br />
für <strong>de</strong>n Ausbau erneuerbarer Energien<br />
auf die Stromverbraucher umgelegt.<br />
Für beson<strong>de</strong>rs stromintensive<br />
Unternehmen enthält das EEG eine<br />
Ausgleichsregelung, mit <strong>de</strong>r die Zusatzlasten<br />
wie<strong>de</strong>r ein Stück weit zurückgenommen<br />
wer<strong>de</strong>n. Durch eine<br />
En<strong>de</strong> 2006 in Kraft getretene Än<strong>de</strong>rung<br />
<strong>de</strong>s EEG beträgt diese Umlage<br />
für beson<strong>de</strong>rs stromintensive Unternehmen<br />
inzwischen „lediglich“ 0,05<br />
Branchenverteilung <strong>de</strong>s privilegierten Letztverbrauchs nach § 16 EEG<br />
für 2008<br />
Cent pro Kilowattstun<strong>de</strong>. Für eine<br />
<strong>Alu</strong>miniumhütte summiert sich die<br />
Zahl hinter <strong>de</strong>m Komma <strong>de</strong>nnoch auf<br />
einen Millionenbetrag. Im Auftrag <strong>de</strong>s<br />
BMU hat das Bun<strong>de</strong>samt für Wirtschaft<br />
und Ausfuhrkontrolle (BAFA)<br />
über die nach dieser Regelung ein-<br />
gereichten Anträge entschie<strong>de</strong>n und<br />
zum Jahreswechsel 2007/08 die Beschei<strong>de</strong><br />
versandt.<br />
Die BAFA setzt für je<strong>de</strong> antragsberechtigte<br />
Abnahmestelle individuelle<br />
Prozentsätze fest. Diese bil<strong>de</strong>n <strong>de</strong>n<br />
eigentlichen Kern <strong>de</strong>r Regelung. Sie<br />
legen für das jeweils folgen<strong>de</strong> Kalen<strong>de</strong>rjahr<br />
fest, welcher Anteil <strong>de</strong>s<br />
an „privilegierten Abnahmestellen“<br />
bezogenen Stroms maximal aus EEG-<br />
Quellen stammen muss, unabhängig<br />
von <strong>de</strong>r jeweils im Folgejahr tatsäch-<br />
lich bezogenen<br />
Strommenge.<br />
In die Berechnung<br />
fließen<br />
dabei u. a. die<br />
nachzuweisen<strong>de</strong>ntatsächlichen<br />
Kosten<br />
<strong>de</strong>s nicht nach<br />
EEG vergüteten<br />
Stroms ein. Die<br />
in <strong>de</strong>n Beschei<strong>de</strong>n für die einzelnen<br />
Abnahmestellen festgeschriebenen<br />
Begrenzungssätze unterschei<strong>de</strong>n sich<br />
daher in <strong>de</strong>m Maße, wie die Kosten<br />
<strong>de</strong>s konventionell bezogenen Stroms<br />
bei <strong>de</strong>n jeweiligen Energieversorgungsunternehmen<br />
differieren.<br />
Für 2008 hat die BAFA eine so<br />
genannte privilegierte Strommenge<br />
von insgesamt<br />
75.874 GWh<br />
ermittelt, die<br />
nicht mit <strong>de</strong>m<br />
vollen, son<strong>de</strong>rn<br />
begrenzten<br />
EEG-Anteil<br />
abzunehmen<br />
ist. Hiervon<br />
entfallen etwa<br />
94 Prozent<br />
(71.283 GWh)<br />
auf Unternehmen<br />
<strong>de</strong>s produzieren<strong>de</strong>n<br />
Gewerbes. Diese Strommenge liegt<br />
damit etwa fünf Prozent über <strong>de</strong>m<br />
Ergebnis <strong>de</strong>s Bescheidverfahrens für<br />
2007 (72.040 GWh).<br />
Die Zahl <strong>de</strong>r begünstigten Unternehmen<br />
liegt 2008 bei insgesamt 426.<br />
Sie ist damit gegenüber <strong>de</strong>m Vorjahr<br />
um 11,5 Prozent gestiegen. Auch die<br />
Zahl <strong>de</strong>r insgesamt bewilligten Begrenzungsbeschei<strong>de</strong><br />
hat sich <strong>de</strong>utlich<br />
erhöht (+15%). Hauptgrund für diesen<br />
Anstieg dürfte sein, dass angesichts<br />
steigen<strong>de</strong>r Strompreise eine wachsen<strong>de</strong><br />
Zahl von Unternehmen das<br />
Kriterium eines mehr als 15-prozentigen<br />
Anteils <strong>de</strong>r Stromkosten an <strong>de</strong>r<br />
Bruttowertschöpfung erfüllt.<br />
Zwischen <strong>de</strong>n einzelnen Branchen<br />
bestehen <strong>de</strong>utliche Unterschie<strong>de</strong><br />
beim jeweiligen Stromverbrauch. So<br />
Regelung Entlastungswirkung für die durch § 16<br />
EEG begünstigten Unternehmen in 2008<br />
Konzessionsabgabe 1.300 Mio. Euro<br />
Stromsteuer 800 Mio. Euro<br />
KWKG 60 bis 70 Mio. Euro<br />
EEG 650 Mio. Euro<br />
Überschlägige Abschätzung <strong>de</strong>r 2008 zu erwarten<strong>de</strong>n finanziellen<br />
Entlastungen bei <strong>de</strong>n durch § 16 EEG begünstigten Unternehmen<br />
haben die begünstigten Unternehmen<br />
mit <strong>de</strong>m höchsten Stromverbrauch<br />
aus <strong>de</strong>n Bereichen <strong>Alu</strong>minium und<br />
Chemie jeweils einen Jahresstrombezug<br />
von mehreren Tausend GWh.<br />
Von <strong>de</strong>r Regelung profitieren in<br />
<strong>de</strong>r Branche „Erzeugung und erste<br />
Bearbeitung von NE-Metallen“ 19<br />
Unternehmen mit einem privilegierten<br />
Letztverbrauch* von 10.653<br />
GWh; in <strong>de</strong>r Metallerzeugung und -<br />
bearbeitung sind es 33 Unternehmen<br />
mit einem Letztverbrauch von 1.966<br />
GWh. Die vier Branchen NE-Metalle,<br />
Chemie, Eisen/Stahl und Papier stellen<br />
etwa drei Viertel <strong>de</strong>s gesamten<br />
privilegierten Letztverbrauchs.<br />
Die BAFA führt darüber hinaus an,<br />
dass Son<strong>de</strong>rregelungen bei <strong>de</strong>r Ökosteuer,<br />
im Kraft-Wärme-Koppelungsgesetz<br />
sowie bei <strong>de</strong>n Konzessionsabgaben<br />
<strong>de</strong>n privilegierten Strombezug<br />
<strong>de</strong>r 2008 begünstigten Unternehmen<br />
zusätzlich in einer Größenordnung<br />
von gut zwei Milliar<strong>de</strong>n Euro (BAFA-<br />
Schätzung) verbilligen (s. Tabelle).<br />
* Beim sog. privilegierten Letztverbrauch han<strong>de</strong>lt<br />
es sich um die Stromverbräuche, die die<br />
antragstellen<strong>de</strong>n Unternehmen zur Jahresmitte<br />
auf Grundlage <strong>de</strong>s letzten abgeschlossenen Geschäftsjahres<br />
geltend machen.<br />
28 ALUMINIUM · 1-2/2008
ALUMINIUM · 1-2/2008<br />
ECONOMICS<br />
29
ALUMINIUM SMELTING INDUSTRY<br />
Primary aluminium activities<br />
at the turn of the year 2007/08<br />
R. P. Pawlek, Sierre<br />
This summary by continent reveals<br />
record global expansion<br />
with new smelters being built in<br />
areas where there is cheap energy.<br />
But there is also continued concentration<br />
of the market as major<br />
players merge or buy out others.<br />
This overview is divi<strong>de</strong>d into continents.<br />
Africa<br />
During 2007, Dubai <strong>Alu</strong>minium Co<br />
(Dubal) signed a joint venture <strong>de</strong>al<br />
with Mubadala Development Co, Algerian<br />
energy company Sonatrach,<br />
and utility firm Sonelgaz to build<br />
Algeria’s first 700,000 tpy aluminium<br />
smelter on the west coast in the<br />
Béni Saf region with an investment of<br />
US$5bn.<br />
Rio Tinto Alcan signed an amen<strong>de</strong>d<br />
agreement with the government<br />
of Cameroon on access to water resources<br />
for the construction of a new<br />
1,000 MW hydro power system in the<br />
West African country. That agreement<br />
paves the way for the start of technical<br />
studies on a potential 400,000 tpy<br />
greenfield smelter. A go-ahead <strong>de</strong>cision<br />
on the smelter project is expected<br />
by the end of 2009. This project<br />
is separate from a previously-agreed<br />
study on the expansion of the existing<br />
90,000 tpy E<strong>de</strong>a smelter operated as a<br />
joint venture between the government<br />
and Rio Tinto Alcan. The brownfield<br />
project, lifting capacity to 300,000 tpy,<br />
continues to make progress.<br />
Century <strong>Alu</strong>minum Co. signed a<br />
memorandum of un<strong>de</strong>rstanding with<br />
the Republic of Congo for the exclusive<br />
right to <strong>de</strong>velop a bauxite mine,<br />
alumina refinery and aluminium<br />
smelter.<br />
BHP Billiton signed an agreement<br />
with the government of the Democratic<br />
Republic of Congo (DRC) to<br />
jointly investigate the <strong>de</strong>velopment<br />
of a 800,000 tpy aluminium smelter.<br />
Russia’s aluminium producer UC<br />
Rusal closed a <strong>de</strong>al to acquire a ma-<br />
jority stake in the <strong>Alu</strong>minium<br />
Smelter Company of Nigeria<br />
(Alscon) in Akwa Ibom from<br />
the Nigerian Bureau of Public<br />
Enterprises. The transaction<br />
will add almost 153,000<br />
tpy to Rusal’s aluminium<br />
production capacity. The<br />
smelter should go online by<br />
the end of 2007. Once fully<br />
operational, the smelter can<br />
provi<strong>de</strong> up to 1,800 jobs.<br />
Furthermore, Rusal announced<br />
it could partner<br />
South African authorities in<br />
the construction of an energy<br />
and metallurgical complex.<br />
The South African government<br />
expressed interest in<br />
working with Rusal on the<br />
project, which would inclu<strong>de</strong><br />
building a 750,000 tpy capacity<br />
aluminium smelter and a<br />
1,300 MW coal-fired power plant.<br />
Alcan signed a contract worth<br />
more than US$100m with a joint<br />
venture consisting of SNC-Lavalin,<br />
Hatch, and Murray & Roberts for the<br />
front-end engineering <strong>de</strong>sign (FEED)<br />
and management of the first phase<br />
of the proposed Coega <strong>Alu</strong>minium<br />
smelter (360,000 tpy). South African<br />
power supplier Eskom will take a 15%<br />
stake in the smelter.<br />
North America<br />
Alcan signed a US$130m contract<br />
with the French energy company<br />
Areva for the <strong>de</strong>sign, engineering and<br />
construction of a new high-voltage<br />
sub-station that will power Alcan’s<br />
planned AP50 pilot plant in Saguenay,<br />
Quebec, Canada.<br />
Alcan also signed a contract with<br />
Bechtel to produce a <strong>de</strong>tailed feasibility<br />
study for the planned expansion<br />
of Alcan’s Kitimat smelter in British<br />
Columbia. Alcan announced its intention<br />
to lift capacity at Kitimat from the<br />
current 280,000 tpy to 400,000 tpy<br />
over a 2009 to 2011 timeframe.<br />
Alcan’s Kitimat smelter in British Columbia<br />
Alcoa, USA, announced on 7 May 2007<br />
to make an offer to acquire all of the<br />
outstanding common shares of Alcan<br />
for US$58.60 in cash and 0.4108 of a<br />
share of Alcoa common stock for each<br />
outstanding common share of Alcan.<br />
Based on Alcoa’s closing stock price<br />
on 4 May 2007, the offer had a value of<br />
US$73.25 per Alcan share or approx.<br />
US$33bn in enterprise value, but was<br />
then outbid by Rio Tinto.<br />
On 12 July Rio Tinto announced<br />
its friendly US$38.1bn all-cash offer<br />
for Alcan. The offer of US$101 per<br />
share represents a 32.8% premium<br />
to Alcoa’s offer of US$76.03 per<br />
share, based on Alcoa’s share price<br />
of 11 July. Unlike Alcoa’s hostile bid,<br />
Rio Tinto has the backing of Alcan’s<br />
board. On 25 October, Alcan and Rio<br />
Tinto group following the successful<br />
offer for Alcan by a subsidiary of Rio<br />
Tinto, became the global aluminium<br />
producer known as Rio Tinto Alcan.<br />
The Alcan name was <strong>de</strong>listed on the<br />
respective stock exchanges on 15<br />
November. Rio Tinto is now itself<br />
the object of takeover bids: both BHP<br />
Billiton and China Investment �<br />
30 ALUMINIUM · 1-2/2008<br />
Photo: Rio Tinto Alcan
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ALUMINIUM SMELTING INDUSTRY<br />
Corporation have ma<strong>de</strong> rival bids.<br />
Alcoa’s Intalco smelter restarted a<br />
second potline at its Ferndale, Washington,<br />
operation. With the first molten<br />
metal poured, the operation’s capacity<br />
increased some 90,000 tonnes in<br />
2007. The smelter has idled two potlines<br />
since April 2003, and the restart<br />
brings the plant’s output to 180,000<br />
tpy, two-thirds of its rated capacity.<br />
Alcoa restarted one line at its Tennessee<br />
aluminium smelter. That line<br />
had been involuntarily idled due to a<br />
direct lighting strike in a severe electrical<br />
storm in mid-April. The potline<br />
produces about 107,000 tpy and was<br />
again fully operational at the end of<br />
June.<br />
Xstrata sold the aluminium business<br />
it inherited from its acquisition of<br />
Falconbridge in 2006 to private equity<br />
firm Apollo Management LP for some<br />
US$1.15bn in cash.<br />
Northwest <strong>Alu</strong>minum Specialties<br />
signed an agreement to dismantle the<br />
long-idled aluminium smelter it owns<br />
in The Dalles, Oregon and to restore<br />
the site. Northwest has contracted<br />
this work to Pro-SE Services Inc., a<br />
Californian company that <strong>special</strong>izes<br />
in engineering and <strong>de</strong>molition services,<br />
to be completed during 2009. In<br />
October Northwest <strong>Alu</strong>minum Co did<br />
not exercise its option to receive 100<br />
MW of power from Bonneville Power<br />
Administration (BPA). As a result, the<br />
100 MW will be divi<strong>de</strong>d proportionally<br />
between Alcoa and Columbia<br />
Falls <strong>Alu</strong>minum, owned by Glencore<br />
International. Alcoa received an additional<br />
70 MW to bring it up to 390<br />
MW and Columbia Falls will get 30<br />
MW bringing its total to 140 MW.<br />
South America<br />
Argentine aluminium producer <strong>Alu</strong>ar<br />
geared up to start bringing online its<br />
newly-constructed smelter expansion.<br />
The project lifted the plant capacity<br />
from 280,000 tpy to 410,000 tpy<br />
and energized 144 new cells. The first<br />
phase expansion, which ad<strong>de</strong>d 130,000<br />
tpy new capacity in an US$850m<br />
investment, was inaugurated on 3<br />
September. <strong>Alu</strong>ar confirmed it will<br />
move ahead immediately with a new<br />
US$400m investment at its Puerto<br />
Madryn smelter to raise primary alu-<br />
minium capacity by another 105,00<br />
tpy to 515,000 tpy by late 2009.<br />
Brazilian aluminium producer<br />
CBA started commissioning the next<br />
stage capacity increase at its Sorocaba<br />
aluminium smelter, expanding plant<br />
capacity from the current 405,000<br />
tpy to 475,000 tpy. Cia Brasileira do<br />
<strong>Alu</strong>minio (CBA) announced it may expand<br />
its primary aluminium smelting<br />
capacity in Sao Paulo state to 700,000<br />
tpy from the current 475,000 tpy.<br />
Alcoa announced investments in<br />
the Serra do Facaño hydroelectric<br />
power project to be built on the Sao<br />
Marcos River in Brazil’s central region.<br />
Alcoa will hold 35% of the new<br />
company. The investment is part of<br />
Alcoa’s long-term strategy of <strong>de</strong>veloping<br />
energy projects in Latin America<br />
to support its smelters and to move<br />
toward self-sufficiency for its energy<br />
needs.<br />
The presi<strong>de</strong>nt of Guyana used a<br />
trip to Moscow to sign a letter of intent<br />
with Rusal on the construction of an<br />
integrated aluminium complex in the<br />
South American country.<br />
Chinese alumina producer Bosai<br />
Minerals Group announced plans<br />
to construct an 800,000 tpy alumina<br />
refinery and 400,000 tpy aluminium<br />
smelter in Guyana. For this, Bosai<br />
Minerals intends to invest 10bn yuan<br />
(US$1.3bn) in building facilities and a<br />
1,000 MW hydro power plant in Guyana<br />
within the next five years.<br />
The governments of Venezuela<br />
and Nicaragua announced a possible<br />
strategic alliance that could see the<br />
<strong>de</strong>velopment of an aluminium smelter<br />
in Nicaragua. Studies are un<strong>de</strong>rway<br />
in Nicaragua to create a company to<br />
produce aluminium for the Nicaraguan<br />
and Latin American markets.<br />
A group of investors announced<br />
plans to build an aluminium smelter<br />
in the Republic of Suriname. Plans<br />
for the 250,000 tpy smelter were disclosed<br />
by Bisram Chan<strong>de</strong>rbosh, presi<strong>de</strong>nt<br />
of Suriname Industrial Engineering<br />
& Vehicle Services.<br />
The second aluminium smelter<br />
project planned for the Caribbean<br />
country of Trinidad & Tobago was<br />
running late due to environmental<br />
concerns. The first project – the<br />
340,000 tpy plant proposed by Alcoa<br />
– has already been put on the<br />
back-burner after the government<br />
was forced to back down on its proposed<br />
location un<strong>de</strong>r pressure from<br />
environmental lobbying. The second<br />
project, <strong>Alu</strong>trint, envisages a smaller<br />
125,000 tpy smelter.<br />
UC Rusal and Corporacion Venezolana<br />
<strong>de</strong> Guayana (CVG) signed a<br />
letter of intent to explore alumina and<br />
aluminium projects in Venezuela.<br />
Asia<br />
Dubal and Mubadala Development<br />
Co, a wholly owned investment vehicle<br />
of the government of the Emirate<br />
of Abu Dhabi, signed a joint venture<br />
for the <strong>de</strong>velopment of Emirates <strong>Alu</strong>minium<br />
(Emal), which plans to build<br />
a 1.4m tpy aluminium smelter in Abu<br />
Dhabi. Construction of the smelter<br />
is slated for two phases, the first of<br />
which is projected to cost US$5bn<br />
and the second US$3bn. The smelter<br />
is to be located at the Khalifa Port and<br />
Industrial Zone in Abu Dhabi.<br />
Rio Tinto also announced plans<br />
to <strong>de</strong>velop a 550,000 tpy aluminium<br />
smelter together with Abu Dhabi Basic<br />
Industries Group (Adbic) at a cost<br />
of about US$5bn.<br />
<strong>Alu</strong>minium Bahrain (Alba) once<br />
more announced plans to raise aluminium<br />
smelting capacity by a further<br />
320,000 tpy to more than 1m tpy, and<br />
is looking to expand through joint<br />
ventures in other Gulf countries. Alba<br />
intends to install a sixth reduction line<br />
at an estimated cost of US$1.7bn to<br />
take capacity to 1.2m tpy.<br />
Anshun Huangguoshu <strong>Alu</strong>minium<br />
Co, a privately-owned producer based<br />
in China’s southern Guizhou province,<br />
doubled capacity to 200,000 tpy.<br />
Guizhou Liupanshui Shuangpai<br />
<strong>Alu</strong>minium Co commissioned a<br />
50,000 tpy project, doubling its total<br />
capacity to 100,000 tpy.<br />
In North China, Shaanxi Changhong<br />
<strong>Alu</strong>minium Co is building<br />
a 100,000 tpy aluminium project,<br />
scheduled to come on stream by June<br />
or July 2007.<br />
<strong>Alu</strong>minium Corporation of China<br />
(Chalco) announced plans to buy three<br />
other aluminium smelters. The acquisitions<br />
increase Chalco’s aluminium<br />
capacity and market competitiveness,<br />
Chalco’s listed subsidiaries Shandong<br />
32 ALUMINIUM · 1-2/2008
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
<strong>Alu</strong>minium Industry Co (SAIC) and<br />
Lanzhou <strong>Alu</strong>minium Co (LAC) said<br />
in separate statements. Chinalco is to<br />
buy 80% of the Inner Mongolian government’s<br />
wholly owned Baotou <strong>Alu</strong>minium<br />
group, which in turn owns<br />
55% of BAC Chinalco, and received<br />
government approval to buy a 72%<br />
stake in Shaanxi Nonferrous Metals<br />
Group, which in turn owns 70.9% of<br />
Tongchuan, and is also to buy 100%<br />
in Liancheng. BAC produced 307,000<br />
tonnes in 2006, Tongchuan 270,000<br />
tonnes and Liancheng 155,000 tonnes.<br />
Chalco is looking to take full ownership<br />
of SAIC and LAC in a US$1bn<br />
<strong>de</strong>al that will enable it to list on the<br />
Shanghai Stock Exchange.<br />
China’s Aba <strong>Alu</strong>minium Plant in<br />
Sichuan province completed expansion<br />
works and double its ingot capacity<br />
to 40,000 tpy in June.<br />
Shanxi Guanlu <strong>Alu</strong>minium announced<br />
plans to expand ingot capacity<br />
by 100,000 tpy on its existing 200<br />
kA line with 70,000 tpy current capacity.<br />
The third, a 300 kA potline with a<br />
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capacity of 200,000 to 220,000 tpy is a<br />
joint venture with Chalco (59%).<br />
Datun <strong>Alu</strong>minium in Jiangsu province<br />
started expansion works on its<br />
ingot capacity in 2007 which will lift<br />
capacity by 150,000 tpy to 260,000 tpy<br />
from the current 110,000 tpy.<br />
China suspen<strong>de</strong>d the construction<br />
of Qiya <strong>Alu</strong>minium Industry Group’s<br />
150,000 tpy aluminium smelter, because<br />
it did not have the necessary<br />
environmental approval.<br />
Shanxi Zhenxin Group had to stop<br />
construction of the second phase of<br />
its 200,000 tpy aluminium smelter<br />
project after the environmental protection<br />
agency of China accused the<br />
company of flouting environmental<br />
laws. The first phase of the project,<br />
which was completed in 2002, remains<br />
in production.<br />
Century <strong>Alu</strong>minum Company<br />
signed a memorandum of un<strong>de</strong>rstanding<br />
(MoU) with the Guangxi<br />
Investment Group Company (GIG)<br />
to explore the feasibility of <strong>de</strong>veloping<br />
an aluminium smelter project and<br />
for <strong>Alu</strong>minium DC<br />
casting<br />
Drache<br />
umwelttechnik<br />
related bauxite mine and alumina refinery<br />
in China.<br />
At least 14 people were killed and<br />
another 59 injured in a molten aluminium<br />
spillage at a casting plant<br />
owned by a subsidiary of China’s<br />
Weiqiao <strong>Alu</strong>minium. The acci<strong>de</strong>nt<br />
happened on 19 August, when molten<br />
aluminium reacted with cooling water<br />
at the plant. The reaction caused an<br />
explosion of steam that blew the roof<br />
of the building, killing workers who<br />
were holding a meeting at the time.<br />
Alcoa sold its equity holdings in<br />
the <strong>Alu</strong>minium Corporation of China<br />
Ltd (Chalco) through a placement<br />
of shares for approx. HK$15.3bn<br />
(US$2.0bn).<br />
Chalco acquired Shaanxi Tongchuan<br />
<strong>Alu</strong>minium Co at the end of<br />
2007. The acquisition of Tongchuan<br />
boosts Chalco’s aluminium by 250,000<br />
tpy to 3.75m tpy currently.<br />
China’s Mimetals Corp’s alumina<br />
and aluminium arm, Minmetals<br />
Resources Limited (MRL)<br />
announced investments of 680m �<br />
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for <strong>Alu</strong>minium DC<br />
casting<br />
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33 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 33
ALUMINIUM SMELTING INDUSTRY<br />
yuan (US$90m) in Qinghai Province<br />
Investment Group(QIG), an aluminium<br />
smelter and hydropower producer.<br />
Vimetco acquired a Chinese aluminium<br />
producer with 110,000 tpy<br />
capacity for around US$35m. Majority-owned<br />
Henan Zhongfu Industry<br />
Co paid 266m yuan (US$35m) for<br />
Lifeng <strong>Alu</strong>minium, which is located<br />
in Linzhou, Henan province. Lifeng<br />
<strong>Alu</strong>minium has a workforce of 1,300.<br />
At the end of 2007, China announced<br />
gui<strong>de</strong>lines for those who<br />
wish to enter the domestic aluminium<br />
industry, according to the National <strong>de</strong>velopment<br />
and Reform Commission.<br />
All new <strong>de</strong>velopment projects in the<br />
aluminium sector, including mining,<br />
alumina refining, primary smelting<br />
and recycling, as well as fabrication<br />
plants, must abi<strong>de</strong> by all requirements<br />
of the various state <strong>de</strong>partments.<br />
These inclu<strong>de</strong> basic requirements for<br />
proper land use, safety and environmental<br />
regulations. Un<strong>de</strong>r the gui<strong>de</strong>lines,<br />
smelting facilities cannot be<br />
built within 1 km of protected regions,<br />
which inclu<strong>de</strong>: water preservation<br />
areas, protected farming areas, protected<br />
natural reservations, famous<br />
scenic attractions, major cities and<br />
their nearby surrounding countrysi<strong>de</strong>,<br />
hospitals, as well as food, medical<br />
and electronic business. For new<br />
primary smelting projects, approval is<br />
also required from the State Council’s<br />
investment management division. In<br />
the near term, only upgrading projects<br />
to suit environmental requirements<br />
and to replace outdated machinery<br />
are being consi<strong>de</strong>red for approvals.<br />
These projects also require guaranteed<br />
alumina feed supply, sufficient<br />
power supply, and efficient transport<br />
conditions.<br />
In February 2007, India’s top nonferrous<br />
producer Hindalco Industries<br />
agreed a friendly takeover bid<br />
for Novelis in a <strong>de</strong>al that values the<br />
North American aluminium company<br />
at about US$6bn, including about<br />
US$ 2.4bn of <strong>de</strong>bt. Hindalco produces<br />
about 429,000 tpy of primary aluminium,<br />
and is planning a greenfield expansion<br />
that will take its capacity to<br />
1.5m tpy by 2011. On 15 May Hindalco<br />
completed the US$6bn purchase of<br />
Novelis, which became a subsidiary of<br />
Mumbai-based company.<br />
Hindalco Industries proved a coalmining<br />
joint venture to feed its much<br />
<strong>de</strong>layed 500,000 tpy integrated aluminium<br />
smelter project in Orissa.<br />
Emirate of Ras Al-Khaimah agreed<br />
a US$2bn joint venture with the government<br />
of Andhra Pra<strong>de</strong>sh to build<br />
an alumina refinery and an aluminium<br />
smelter in the eastern Indian state.<br />
The alumina refinery will produce 1m<br />
tpy of alumina while the smelter will<br />
have an initial capacity of 250,000<br />
tpy which may be doubled at a later<br />
date.<br />
Vedanta Resources announced<br />
plans to more than double capacity<br />
to 900,000 tpy of primary aluminium<br />
by 2009, once it has brought its new<br />
500,000 tpy greenfield project in<br />
Orissa on stream. The smelter will<br />
be commissioned early next year and<br />
ramped up to reach full capacity in<br />
early 2009.<br />
The Indian aluminium producer<br />
Balco signed an MoU with the state of<br />
Chattisgarh on a major expansion of<br />
its Korba smelting complex. The MoU<br />
provi<strong>de</strong>s for a further investment of<br />
US$2bn to lift capacity by a further<br />
650,000 tpy, bringing total capacity<br />
at the Korba complex close to the1m<br />
tpy level.<br />
Dubal and Larsen & Toubro proposed<br />
to jointly set up a 3m tpy alumina<br />
refinery and a 220,000 tpy aluminium<br />
smelter in the Indian state of<br />
Orissa.<br />
India’s state-owned National <strong>Alu</strong>minium<br />
Company (Nalco) announced<br />
plans to double its alumina capacity<br />
to 3m tpy and smelter capacity to<br />
710,000 tpy. No time frame has been<br />
scheduled, but work towards these<br />
third-phase targets as well as a 700<br />
MW power plant will begin at the end<br />
of 2008, when Nalco’s current expansion<br />
ends. Nalco is in the process of<br />
raising alumina capacity from 1.57m<br />
tpy to 2.1m tpy, and its smelter capacity<br />
from 350,000 tpy to 460,000 tpy.<br />
Ras-Al-Khaima Investment Authority<br />
(Rakia), a provincial investment<br />
company of the United Arab<br />
Emirates, is planning to invest US$2bn<br />
in a greenfield integrated aluminium<br />
complex in the India state of Andhra<br />
Pra<strong>de</strong>sh. Rakia has singed an agreement<br />
with with the Andhra Pra<strong>de</strong>sh<br />
Mineral Development Authority for<br />
bauxite reserves to feed a planned<br />
facility in Visakhapatnam. Rakia consi<strong>de</strong>rs<br />
a 1.5m tpy alumina refinery and<br />
a 350,000 tpy smelter.<br />
The Indian aluminium industry expects<br />
to invest Rs1,000bn (US$25bn)<br />
over the next five years, boosting installed<br />
aluminium smelting capacity<br />
from the existing 1.1m tpy to 4m tpy.<br />
The announcement at the end of 2007<br />
also said consumption of aluminium<br />
in India is growing at 18% per year<br />
compared with the global 4.4%. By<br />
2015, the Indian aluminium use will<br />
grow to 2.75m tpy.<br />
In June 2007, India’s Nalco was<br />
looking for partners to set up a 500,000<br />
tpy aluminium smelter project in Indonesia.<br />
However it was not revealed<br />
when the smelter might be built, or<br />
what kind of partnership Nalco was<br />
looking for.<br />
Iran <strong>Alu</strong>minium Company (Iralco)<br />
officially inaugurated its new Hormozal<br />
smelter to complement its existing<br />
120,000 tpy Al Mahdi smelter.<br />
The first phase of the project has a<br />
capacity of 35,000 tpy and that will<br />
rise to 110,000 tpy when the second<br />
and the third phases are completed by<br />
March 2009. The expansion is being<br />
conducted in cooperation with China’s<br />
Non-Ferrous Metal Industry’s<br />
Foreign Engineering & Construction<br />
Company Limited (NFC).<br />
Gulf aluminium producer Dubal<br />
will supply its proprietary technology<br />
for an expansion of the Al Mahdi<br />
smelter in Iran. The Hormozal expansion<br />
of Al Mahdi will see the addition<br />
of a second potline with a capacity of<br />
147,000 tpy, lifting total smelter capacity<br />
to 257,000 tpy<br />
Kazakhstan <strong>Alu</strong>minium Smelter<br />
(KAS), part of Kazakh metals and mining<br />
group Eurasian Natural Resources<br />
Corporation (ENRC), has signed a<br />
US$292.8m credit agreement with<br />
the Export-Import Bank of China<br />
(Eximbank). Building the smelter was<br />
complete by the end of 2007, and it<br />
will come on stream in three stages,<br />
with initial output at 62,500 tpy, rising<br />
to 125,000 tpy by 2008 and 250,000<br />
tpy by 2011.<br />
UC Rusal was in talks with the Kazakh<br />
government about the possibility<br />
of building an aluminium and �<br />
34 ALUMINIUM · 1-2/2008
Photo: Norsk Hydro<br />
ALUMINIUM SMELTING INDUSTRY<br />
energy complex in the central Asian<br />
country. UC Rusal has approached<br />
the Kazakh authorities with a proposal<br />
to invest US$3.5bn in building<br />
a 500,000 tpy aluminium smelter and<br />
1m tpy alumina refinery.<br />
UC Rusal resumed exploring opportunities<br />
for building an energy and<br />
metals complex in Kyrgyzstan, after its<br />
failure to accomplish a similar project<br />
in neighbouring Tajikistan.<br />
Rio Tinto announced it might sign<br />
an agreement with the Malaysian<br />
government for the construction of<br />
a 1.5m tpy aluminium smelter in the<br />
state of Sawarak. Many major aluminium<br />
companies around the world<br />
are said to be eager to participate in<br />
the project, including Alcoa and BHP<br />
Billiton, as well as China’s aluminium<br />
producer Shandong Luneng Group<br />
and energy company Sinohydro.<br />
In August Rio Tinto and Malaysia’s<br />
Cahya Mata Sarawak (CMS) signed a<br />
heads of agreement for the proposed<br />
<strong>de</strong>velopment of a 750,000 tpy aluminium<br />
smelter in the Malaysian state of<br />
Sarawak. In October Bechtel had been<br />
appointed to un<strong>de</strong>rtake an engineering<br />
study of the proposed US$2.2bn<br />
new aluminium smelter.<br />
Alcoa was also in talks with the<br />
Malaysian government about the<br />
construction of a 1m tpy aluminium<br />
smelter in the state of Sarawak.<br />
Qatalum, the new aluminium<br />
smelter company in Qatar, a joint<br />
venture between Qatar Petroleum<br />
and Hydro <strong>Alu</strong>minium AS, has<br />
awar<strong>de</strong>d the contract for its 1250 MW<br />
power plant to a consortium integrat-<br />
Qatalum aluminium plant site<br />
ed of General Electric and Doosan<br />
Heavy Industries Construction Co.,<br />
Ltd. Qatalum will be a state-of-theart<br />
installation for 585,000 tpy of<br />
high quality aluminium using Hydro<br />
technology. The <strong>de</strong>sign incorporates<br />
an option to double the capacity to<br />
1.2m tpy of aluminium. During the<br />
construction phase at the Mesaieed<br />
Industrial City, Qatalum will generate<br />
about 5,500 jobs, and once in operation<br />
during 2010, Qatalum will provi<strong>de</strong><br />
1,000 permanent jobs. The capital<br />
investment estimate for the total<br />
Qatalum project is approx. US$5.6bn.<br />
Norsk Hydro and Qatar Petroleum laid<br />
the foundation stone on 19 November<br />
at the 1.7 square km site in Mesaieed<br />
Industrial City, south of Doha.<br />
Two Chinese state entities, China<br />
Non-ferrous Metal Industry’s Foreign<br />
Engineering and Construction Co Ltd<br />
(NFC) and China National Machinery<br />
Industry Corporation (Sinomach),<br />
signed an agreement with Saudi Arabian<br />
company Western Way for Industrial<br />
Development Co (WWIDC) to<br />
build an integrated alumina-aluminium<br />
mega-complex at Jazan in Saudi<br />
Arabia. The agreement provi<strong>de</strong>s for a<br />
project with an alumina capacity of<br />
1.6m tpy and a primary metal capacity<br />
of 700,000 tpy for a total investment of<br />
around US$4bn. NFC will take a significant<br />
but as yet undisclosed stake<br />
in the complex, as will US metals<br />
tra<strong>de</strong> house Gerald Metals.<br />
Alcan signed a heads of agreement<br />
with Saudi Arabian mining company<br />
Ma’a<strong>de</strong>n to <strong>de</strong>velop a US$7bn integrated<br />
aluminium mine-to-metal<br />
project, incuding bauxite mining, a<br />
1.6m tpy alumina refinery, a 1,400<br />
MW power plant and a 720,000 tpy<br />
aluminium smelter.<br />
MMC Corp and the Saudi Binladin<br />
Group signed an agreement with <strong>Alu</strong>minum<br />
Corporation of China (Chalco)<br />
to build a second aluminium smelter<br />
at Jazan Economic City (JEC) in Saudi<br />
Arabia at a cost of US$3bn. The smelter<br />
will have a capacity of 1m tpy. The<br />
companies formed joint venture company<br />
Sino-Saudi Jazan <strong>Alu</strong>minium Ltd<br />
to un<strong>de</strong>rtake the project, with Chalco<br />
and a Saudi consortium.<br />
Companies including Norsk Hydro<br />
are reported to be competing to become<br />
partners with Tajikistan’s sole<br />
aluminium produce Tajik <strong>Alu</strong>minium<br />
(Talco), which was once more likely<br />
to have been a target of their litigation.<br />
Having put its disputes with the<br />
smelter behind, Hydro is confi<strong>de</strong>nt<br />
their new partnership will flourish.<br />
At the centre of both companies’ ambitions<br />
is the 500,000 tpy aluminium<br />
smelter, which has been running at<br />
400,000 tpy in recent years. Hydro<br />
<strong>Alu</strong>minium will help mo<strong>de</strong>rnize the<br />
smelter in exchange for increasing<br />
the volume of alumina it supplies to<br />
Talco.<br />
Dubai <strong>Alu</strong>minium (Dubal) announced<br />
plans to raise primary metal<br />
production capacity to 920,000 tpy by<br />
the end of 2008. After the US$230m<br />
ongoing potline 5B and 6B expansion,<br />
Dubal will further raise primary capacity<br />
to 945,000 tpy, and casthouse capacity<br />
to 1.13m tpy. At the end of 2007,<br />
Dubal announced plans to increase<br />
production to 2.5m tpy by 2015.<br />
Russia’s UC Rusal wants to build<br />
a hydro-electric power plant and<br />
an integrated bauxite-to-aluminium<br />
facility in Vietnam’s southern Binh<br />
Phuoc province. The planned aluminium<br />
smelter would have a capacity of<br />
750,000 tpy.<br />
Australia<br />
In October 2007, Rio Tinto’s takeover<br />
offer for Canadian aluminium<br />
producer Alcan received the green<br />
light from the competition watchdogs<br />
of Europe and Australia, and<br />
the US$38.1bn takeover created the<br />
world’s largest aluminium producer.<br />
36 ALUMINIUM · 1-2/2008
ALUMINIUM SPECIALSMELTING<br />
INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Rio Tinto obtained all outstanding<br />
common shares of Alcan and <strong>de</strong>listed<br />
Alcan on 15 November.<br />
In November investors seemed<br />
sure that mining giant BHP Billiton<br />
will continue its US$149bn pursuit of<br />
Rio Tinto, a combination that would<br />
control more than one third of the<br />
world’s iron ore sale. Rio Tinto rejected<br />
BHP Billiton’s 3-for-1 share<br />
offer on 8 November, but share price<br />
movements in London and Australia<br />
indicate investors expect that BHP<br />
Billiton will increase its offer, that the<br />
bid will turn hostile or that another<br />
bid<strong>de</strong>r will emerge. BHP confirmed<br />
its approach to its mining rival and<br />
intends to continue to seek an opportunity<br />
to meet and discuss its proposal<br />
with Rio Tinto.<br />
Europe<br />
<strong>Alu</strong>-Met, Europe’s largest privately<br />
owned extrusion billet producer has<br />
thrown its hat into the ring as a possible<br />
suitor for Corus Group’s primary<br />
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aluminium business in the Netherlands<br />
and Germany. <strong>Alu</strong>-Met, which<br />
is headquartered in Blu<strong>de</strong>nz, Austria,<br />
has two production facilities in Germany.<br />
In Kempten <strong>Alu</strong>-Met produces<br />
55,000 to 60,000 tpy of extrusion billet<br />
while in Nachrodt the capacity<br />
is about 80,000 tpy. The aluminium<br />
smelter in Voer<strong>de</strong>, Germany has a capacity<br />
of 90,000 tpy while the smelter<br />
in Delfzjil, the Netherlands has a capacity<br />
to produce about 110,000 tpy<br />
of primary aluminium.<br />
Carbone Savoie, a subsidiary of<br />
Alcan based in France, announced<br />
plans to invest US$17m to enhance<br />
equipment at the Notre-Dame-<strong>de</strong>-Briançon<br />
and Lannemzan sites in or<strong>de</strong>r<br />
to rapidly meet the needs of its catho<strong>de</strong><br />
products customers.<br />
Anglo-Dutch steelmaker Corus<br />
Group, which is owned by Tata Steel,<br />
put its remaining primary aluminium<br />
business, which inclu<strong>de</strong>s two smelters<br />
in the Netherlands and Germany, up<br />
for sale and has received an expression<br />
of interest from Trimet. In De-<br />
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cember, Corus and <strong>Alu</strong>minium Industrial<br />
Acquisition Company Ltd (AIAC)<br />
signed a non-binding letter of intent<br />
for the proposed acquisition of Corus’<br />
aluminium smelters by an affiliate of<br />
AIAC for an undisclosed sum.<br />
The German aluminium producer<br />
Trimet <strong>Alu</strong>minium AG restarted production<br />
at the idled aluminium smelter<br />
in Hamburg in April. Some 400 employees<br />
were recalled and the official<br />
opening was on May 9. End of 2007 all<br />
270 cells were in full operation.<br />
Hydro <strong>Alu</strong>minium announced<br />
plans to build an aluminium smelter<br />
in Greenland with a capacity of as<br />
much as 300,000 tpy. Such a metal<br />
production would need 500 MW of<br />
power.<br />
The Greenland Home Rule Cabinet<br />
entered into an MoU with aluminium<br />
company Alcoa over co-operation on<br />
a feasibility study for a 340,000 tpy<br />
capacity smelter in Greenland.<br />
A planned expansion of Alcan’s<br />
smelter Isal in Iceland would see the<br />
implementation of Alcan’s AP35 �<br />
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ALUMINIUM SMELTING INDUSTRY<br />
technology, raising the total capacity<br />
to 460,000 tpy. However, Alcan lost<br />
its exclusive rights to power supplies<br />
which would have enabled the company<br />
to expand its Isal smelter.<br />
Alcoa started commissioning the<br />
340,000 tpy Fjaardal smelter and celebrated<br />
the official inauguration at<br />
the beginning of June. To compensate<br />
for slight power project <strong>de</strong>lays, Alcoa<br />
has secured some bridge power, but<br />
reached full capacity at the beginning<br />
of 2008.<br />
Century <strong>Alu</strong>minium of Monterey,<br />
California, is moving ahead with plans<br />
for its second smelter in Iceland. To be<br />
located in Helguvik, approx. 25 miles<br />
south of Reykjavik, the smelter would<br />
have an initial capacity of 150,000 tpy<br />
and could be expan<strong>de</strong>d to 250,000<br />
tpy.<br />
Since July, Century <strong>Alu</strong>minium’s<br />
40,000 tpy has been commissioning<br />
the expansion at its Grundartangi<br />
smelter in Iceland. The ramp-up was<br />
completed at the end of November<br />
2007, lifting capacity at the smelter to<br />
260,000 tpy.<br />
Alcan sold its Vlissingen smelter in<br />
the Netherlands to Klesch & Company<br />
Ltd (Klesch).The transaction closed in<br />
summer 2007. The Vlissingen aluminium<br />
plant employs some 700 people<br />
and has a capacity of 200,000 tpy of<br />
primary aluminium, with a turnover<br />
of approx. US$600m in 2006.<br />
Hydro <strong>Alu</strong>minium of Norway announced<br />
investments of NOK 340m<br />
(US$55.74m) in expanding the four<br />
gas scrubber units at its aluminium<br />
plant at Sunndalsøra. The work will<br />
be complete by November 2008.<br />
On 13 June Hydro cut off power to<br />
the last Sø<strong>de</strong>rberg pots at its Årdal<br />
aluminium smelter. Capacity at Årdal<br />
fell from 220,000 tpy to 180,000 tpy<br />
as a result of the phase-out of the Sø<strong>de</strong>rberg<br />
potline.<br />
At the beginning of July the Norwegian<br />
Ministry of the Environment<br />
conce<strong>de</strong>d temporary emission limits<br />
for the Sø<strong>de</strong>rberg aluminium production<br />
line at Karmøy. The limits are 3.2<br />
kg/h for PAH (polycyclic aromatic hydrocarbons)<br />
and 35 kg/h particulates,<br />
and they postpone the closure of the<br />
Sø<strong>de</strong>rberg line until the end of 2009,<br />
when strict new emission limits come<br />
into force.<br />
Photo: UC Rusal<br />
Alcoa opened its new 280,000 tpy<br />
prebake ano<strong>de</strong> plant in Mosjoen, Norway.<br />
The facility produces ano<strong>de</strong>s for<br />
Alcoa’s Fjardaal aluminium smelter<br />
in Iceland and for the Mosjoen aluminium<br />
smelter in Norway. The companies<br />
spent NOK3bn (US$528m)<br />
on the project, which employs 100<br />
workers.<br />
UC Rusal’s Bratsk smelter<br />
In January 2007, Russia approved in<br />
principle the planned merger between<br />
Rusal, Sual and the alumina assets of<br />
Swiss trading company Glencore. The<br />
new company – United Company<br />
Rusal – will produce 4m tpy of aluminium<br />
and 11m tpy of alumina, with<br />
a workforce of some 110,000 people<br />
in 17 countries on five continents.<br />
The companies also obtained approvals<br />
from anti-trust authorities outsi<strong>de</strong><br />
Russia. On 27 March 2007, Rusal, Sual<br />
and Glencore announced the completion<br />
of the <strong>de</strong>al to combine their assets<br />
and create United Company Rusal.<br />
UC Rusal and HydroOGK, Russia’s<br />
lea<strong>de</strong>r in the area of renewable<br />
energy, began construction of the<br />
Boguchanskiy <strong>Alu</strong>minium Smelter.<br />
The 600,000 tpy will be one of Russia’s<br />
five largest. Total investment<br />
in this project is expected to reach<br />
US$2.3bn. The foundation stone was<br />
laid on 15 May 2007 in the village of<br />
Tayozhny, Krasnoyarsk region.<br />
The construction of a fifth potline<br />
at UC RusAl’s Irkutsk smelter was<br />
on track for completion in the fourth<br />
quarter of 2007. The new line boosts<br />
the plant’s capacity from the existing<br />
290,000 tpy to around 450,000 tpy<br />
once fully ramped up.<br />
UC Rusal started of a major mo<strong>de</strong>rnisation<br />
programme at its giant<br />
Bratsk smelter, which with nameplate<br />
capacity of 983,000 tpy is the world’s<br />
largest single smelter.<br />
In November the Krasnoyarsk<br />
<strong>Alu</strong>minium Smelter completed the<br />
installation of automatic alumina<br />
point-fee<strong>de</strong>rs, having invested over<br />
US$38m.<br />
UC Rusal signed a cooperation<br />
agreement with the government of<br />
Russia’s Saratov region for the construction<br />
of a major energy and metals<br />
complex. The complex will inclu<strong>de</strong><br />
a significant expansion of the Balakovsky<br />
nuclear power plant, with UC<br />
Rusal building the fifth and sixth reactor<br />
blocks generating 2,000 MW, as<br />
well as the construction of the world’s<br />
largest aluminium smelter with a capacity<br />
of 1.05m tpy.<br />
UC Rusal signed an MoU on an<br />
integrated energy/aluminium complex<br />
with the local government of Sakhalin.<br />
Construction of a 2,300 MW<br />
power plant using coal from the Solntsevskiy<br />
coal mine would prece<strong>de</strong> that<br />
of a 750,000 tpy smelter.<br />
At the end of 2007, UC Rusal announced<br />
its aim to lift annual aluminium<br />
production capacity to 6m tpy<br />
and alumina production to17m tpy by<br />
2013. This represents a 50% increase<br />
in current metal production capacity.<br />
Some of that will come through<br />
upgra<strong>de</strong>s to the existing smelter network,<br />
but more will come through<br />
greenfield smelter projects. �<br />
38 ALUMINIUM · 1-2/2008
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Self-lifting crane mo<strong>de</strong>rnizes ol<strong>de</strong>r potlines<br />
D. Mad<strong>de</strong>n, Gladstone<br />
An exciting new <strong>de</strong>velopment<br />
allows smelters to remove and<br />
install whole pots complete with<br />
linings, using a crane <strong>de</strong>sign <strong>de</strong>veloped<br />
by Southern Cross Engineering<br />
(SCE) of New Zealand.<br />
The <strong>de</strong>sign of many ol<strong>de</strong>r smelters<br />
leaves no choice but to reline pots in<br />
situ. By contrast, mo<strong>de</strong>rn smelters are<br />
<strong>de</strong>signed with crane capacity, as well<br />
as built-in transfer facilities, so that<br />
they can complete pot relining outsi<strong>de</strong><br />
the operating pot line. This increases<br />
production by a significant fraction, in<br />
or<strong>de</strong>r of 1%, worth millions of dollars.<br />
Southern Cross Engineering’s unique<br />
crane <strong>de</strong>sign is now finding its way<br />
into existing smelters previously constrained<br />
by their technology and/or<br />
building <strong>de</strong>sign.<br />
The crane and its operation<br />
This <strong>de</strong>sign is unique in that it is transported<br />
to the potline and there lifts itself<br />
onto the existing crane rails using<br />
an on-board hydraulic jacking system.<br />
The complete installation takes about<br />
one hour. The attached lifting beam<br />
can then lift the pot evenly.<br />
The crane is remotely operated<br />
by radio control, so allowing the operator<br />
to carry out all operations from<br />
the floor. Once installed, the crane is<br />
driven to the pot to be removed; there<br />
the pot is attached to the crane via<br />
the <strong>special</strong>ly <strong>de</strong>signed lifting beam,<br />
and is then lifted clear of the existing<br />
pot superstructures. The crane next<br />
transports the pot to the centre passageway,<br />
and loads it onto a trailer for<br />
transport to a pot dig-out building. The<br />
crane then picks up the new, relined<br />
replacement pot, <strong>de</strong>livers it to its position<br />
in the line, and installs it there.<br />
Turn-around time is approximately 2<br />
hours. The crane finally lowers itself<br />
from the rails, and it is then removed<br />
from the potline hall and stored in a<br />
simple shelter, ready for re-use whenever<br />
nee<strong>de</strong>d.<br />
There are many important benefits<br />
of being able to remove the pot<br />
and carry out the relining in a facility<br />
outsi<strong>de</strong> the pot line. The return on<br />
investment (ROI) is realised in a very<br />
short period, in some cases in months<br />
rather than years.<br />
With mo<strong>de</strong>rn smelters pushing the<br />
envelope for ‘world’s best practice’ in<br />
areas of<br />
• Health and safety<br />
• Current efficiency<br />
• Lining life<br />
• DC kilowatts per tonne<br />
it is vital for the ol<strong>de</strong>r smelters to be<br />
creative with their capital spending<br />
in or<strong>de</strong>r to capture the ‘low hanging<br />
fruit’ that offers high returns that are<br />
easily measured.<br />
With metal prices and metal <strong>de</strong>mand<br />
at all time highs, any loss of<br />
metal production due to reconstruction<br />
time constraints becomes an important<br />
issue.<br />
Where are some of the costs incurred<br />
with reconstruction of pots in<br />
situ on the line?<br />
• Lost production, estimated at three<br />
weeks per pot<br />
• Power capacity paid for but not<br />
used<br />
• Daily potline operations disrupted<br />
• Hostile environment for potline<br />
workers<br />
• Low productivity due to working<br />
environment<br />
• Voluminous construction equip-<br />
ment encumbers the potline<br />
• Many construction personnel<br />
working in potline, creating extra<br />
safety issues for operation<br />
• Production labour paid for but not<br />
used.<br />
The following calculations show the<br />
benefits in monetary terms of completing<br />
this work outsi<strong>de</strong> the line for a<br />
typical smelter: These calculations are<br />
based on western world smelter costs,<br />
using the following assumptions:<br />
• Typical plant <strong>de</strong>sign Kaiser P69<br />
• Tonnage 250,000 tpy with 500 pots<br />
• DC kWh/tonne 13,500 at 2.5 cents<br />
per kWh<br />
• Five year lining life with 100<br />
relines per year<br />
• Pot production 1.4 tpd<br />
• Average reconstruction time per<br />
pot 18 days<br />
• LME price US$ 2,500 per tonne<br />
• 900 man hours to reconstruct pot<br />
at US$ 60 per hour<br />
• Based on 1,000 employees.<br />
Lost production<br />
18 days x 100 pots = 1,800 pot-days<br />
1.4 tonnes x 1,800 days = 2,520 tonnes<br />
of lost production<br />
US$ 2,500 x 2,520 tonnes = US$<br />
6,300,000<br />
Lost production income due to reconstruction<br />
in the line is US$6.3m.<br />
Power paid for but not used<br />
2,520 tonnes x 13,500 kWh per tonne<br />
= 34 million kWh at 2.5 cents/kWh =<br />
US$ 850,000<br />
Power paid for but not used is US$<br />
850,000.<br />
�<br />
39 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 39<br />
Photo: Holcan
ALUMINIUM SMELTING INDUSTRY<br />
Excess labour costs<br />
Estimated direct labour reconstruction<br />
productivity loss due to work<br />
constraints associated with working<br />
in an operating pot line; estimated<br />
reconstruction labour efficiencies<br />
captured by reconstructing outsi<strong>de</strong><br />
operational pot line 20%:<br />
900 hours estimated cost to reconstruct<br />
in pot line x 20% = 180 hours.<br />
Extra labour cost to reconstruct in<br />
line: 180 hours x US$ 60 per hour x<br />
100 pots reconstructed per year.<br />
Extra labour cost is US$ 1,080,000.<br />
Plant production labour<br />
paid for but not used<br />
2,520 tonnes lost production = 1% of<br />
total production. Assume that 1,000<br />
people are employed at the plant: 1%<br />
= 10 personnel. Cost per person per<br />
year US$ 60 x 40 hours x 52 weeks<br />
x 10 employees = US$ 1,248,000 per<br />
year.<br />
Extra production labour cost per year<br />
is US$ 1,248,000.<br />
Aggregation: US$ 9,478,000 per year<br />
additional income through usefully<br />
employing otherwise wasted resources<br />
of electrical power and production<br />
labour.<br />
Conclusion<br />
Smelters that currently complete pot<br />
reconstruction in the pot lines should<br />
take a close look at this crane. This<br />
article has only touched the surface<br />
of the benefits, focussing on direct<br />
monetary savings. The long-term consi<strong>de</strong>rations<br />
associated with workers’<br />
health have not been factored in.<br />
Disclaimer<br />
A study of the smelter’s pot room<br />
structure would need to be carried<br />
out to verify its compatibility with<br />
the installation and operation of the<br />
new crane.<br />
Author<br />
Hydraulic pressing<br />
of prebaked ano<strong>de</strong>s for aluminium smelters<br />
A. Kaiser, Wecke<br />
Even though vibrating compaction<br />
has long been the most common<br />
means of forming prebaked<br />
ano<strong>de</strong>s, many plants worldwi<strong>de</strong><br />
still use hydraulic pressing. Improvements<br />
in hydraulic pressing<br />
technology are now available for<br />
prebaked ano<strong>de</strong> production and<br />
may lead to a revival of this well<br />
proven, but temporarily unfashionable<br />
technology. Laeis, a world<br />
leading supplier of high performance<br />
hydraulic presses [1,2] originally<br />
<strong>de</strong>veloped these improvements<br />
for other applications. The<br />
new ano<strong>de</strong> forming concept uses a<br />
hydraulic vacuum press [3] and offers<br />
advantages in process productivity<br />
and flexibility, as well as in<br />
ano<strong>de</strong> quality and environmental<br />
impact.<br />
There have been very few direct comparisons<br />
between vibrated and pressed<br />
ano<strong>de</strong>s [4]. Several production plants<br />
operate both hydraulic presses and<br />
vibrocompactors, but produce different<br />
types of ano<strong>de</strong>s with each forming<br />
process. The few available data can be<br />
summarized as follows: pressed and<br />
vibrated ano<strong>de</strong>s show similar average<br />
values, e. g. comparable apparent<br />
<strong>de</strong>nsity levels (green and baked). On<br />
average, pressed ano<strong>de</strong>s (shaped on<br />
‘old’ hydraulic presses) have lower<br />
air permeability, whereas vibrated<br />
ano<strong>de</strong>s show better specific electrical<br />
resistance and strength values. The<br />
new Laeis pressing concept [5] over-<br />
Dan Mad<strong>de</strong>n is the Managing Director of<br />
Holcan Constructions. He has been associated<br />
with the primar smelting industry<br />
for over 30 years.<br />
comes these disadvantages in electrical<br />
resistance and strength, while<br />
maintaining the advantages.<br />
The new Laeis hydraulic<br />
vacuum press for ano<strong>de</strong>s<br />
Dosing and weighing unit: The cooling<br />
mixer continuously discharges conditioned<br />
and homogenized paste into a<br />
Fig. 1: Schematic drawing of different pressing principles<br />
left: bilateral pressing, middle: HPF pressing principle, right: unilateral pressing<br />
40 ALUMINIUM · 1-2/2008<br />
Illustrations: Laeis
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
dosing unit; this feeds a weighing bin<br />
which measures the paste nee<strong>de</strong>d for<br />
the next pressing stroke. The dosing<br />
and weighing unit maintains an overall<br />
dosing accuracy of ±5 kg and can<br />
work with cycle times of about one<br />
minute. It can be <strong>de</strong>signed as single<br />
or as a twin unit to be used for 1-cavity<br />
respectively 2-cavity moulds, <strong>de</strong>pending<br />
on the size of the ano<strong>de</strong>s to<br />
Parameter Unit Value<br />
Pressing force max. kN<br />
t<br />
Fig. 2: Influence of vertical <strong>de</strong>nsity distribution in a pressed product<br />
be pressed. A reversible conveyor allows<br />
scrap paste to be discharged (e. g.<br />
during start up of the process) without<br />
it going through the weighing system<br />
and the press.<br />
Hydraulic vacuum press: A high<br />
performance hydraulic press type<br />
MEGA 1600 AV is used for the shaping<br />
of the ano<strong>de</strong>s. It belongs to the well<br />
known Laeis HPF press series with the<br />
so-called ‘active mould’ movement<br />
which has been proven as state-of-theart<br />
presses in the refractory industry<br />
for many years. Together with a very<br />
flexible control system, the HPF pressing<br />
principle (Figs. 1 and 2) provi<strong>de</strong>s<br />
the advantages of a bilateral pressing<br />
system (optimum <strong>de</strong>nsification and<br />
controlled <strong>de</strong>nsity distribution over<br />
the height of the ano<strong>de</strong>), but avoids<br />
the traditional disadvantages of such<br />
presses (<strong>de</strong>ep pits up to 6 m necessary,<br />
high costs for foundation works).<br />
The MEGA 1600 AV with a pressing<br />
force of 16,000 kN (1,600 t) has<br />
been specifically adapted for the<br />
production of prebaked ano<strong>de</strong>s. For<br />
instance, it features an exten<strong>de</strong>d die<br />
surface area for pressing ano<strong>de</strong>s up<br />
to about 1700 mm long, about 1200<br />
mm wi<strong>de</strong> and maximum 1200 mm<br />
<strong>de</strong>ep, so as to form ano<strong>de</strong>s of practically<br />
all dimensions used today. The<br />
mould <strong>de</strong>sign allows direct pressing<br />
of stub holes for rodding of the ano<strong>de</strong>s.<br />
A <strong>special</strong> mould filling <strong>de</strong>vice<br />
ensures homogeneous filling of the<br />
pre-weighed paste into the mould (1<br />
or 2 cavities) and a vacuum system<br />
evacuates air from the mould before<br />
compaction. A <strong>special</strong> mould changing<br />
<strong>de</strong>vice is available which can complete<br />
a mould change in less than one<br />
hour. The main performance data of<br />
the MEGA 1600 AV press are summarized<br />
in Table 1.<br />
Press control: The flexible press<br />
control system allows a fully automated<br />
and safe plant operation. It also collects<br />
and stores comprehensive data,<br />
and it provi<strong>de</strong>s for comfortable evaluation<br />
using standard software for individual<br />
data processing. The operator<br />
interface has a clear and easy-to-un<strong>de</strong>rstand<br />
structure <strong>de</strong>signed around<br />
Windows technology with mainly<br />
graphic display (Fig. 3). When ano<strong>de</strong>s<br />
are pressed, the press continuously<br />
monitors the height of each an-<br />
41 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 41<br />
16,000<br />
1,600<br />
Useful die surface max. mm x mm 1200 x 1800<br />
Filling <strong>de</strong>pth max. mm 1200<br />
Time per stroke min. min ≥ 1<br />
Throughput capacity (1 or 2 cavities) pcs/h ≥ 60/120<br />
Height accuracy mm ± 2<br />
Vacuum mbar < 100<br />
Pressing temperature (approx.) °C 110-130<br />
Noise level dBA ≤ 76<br />
Mould changing time h ≤ 1<br />
Table 1: Performance data of hydraulic ano<strong>de</strong> press MEGA 1600 AV<br />
Fig. 3: Main menu of ProVi press control showing the graphic orientation of the<br />
machine/operator interface �
ALUMINIUM SMELTING INDUSTRY<br />
Fig. 4: Pressing regime for pressing to nominal ano<strong>de</strong> height<br />
o<strong>de</strong> and the applied pressure.<br />
Different pressing regimes can be<br />
selected, but for the production of<br />
ano<strong>de</strong>s the standard mo<strong>de</strong> is ‘pressing<br />
to nominal height’ (Fig. 4). Many<br />
individual pressing parameters can be<br />
set and/or changed in or<strong>de</strong>r to optimize<br />
the pressing sequence and the<br />
resulting ano<strong>de</strong> properties. Table 2<br />
shows some of these parameters and<br />
their main effects. The control system<br />
additionally provi<strong>de</strong>s communication<br />
links with external systems, such as<br />
upstream and downstream plant components<br />
as well as host computer.<br />
These links can be used in many different<br />
ways, such as for plant operation<br />
supervision as well as for quality<br />
control, documentation and statistical<br />
evaluation.<br />
Advantages of hydraulic<br />
pressing of ano<strong>de</strong>s<br />
Plant productivity and flexibility:<br />
One of the most important features of<br />
the hydraulic press MEGA 1600 AV<br />
is its high production capacity of up<br />
to 60 or 120 ano<strong>de</strong>s/h (1- or 2-cav-<br />
ity mould) in a single line. For most<br />
ano<strong>de</strong> sizes it can form up to 50 t/h<br />
or even more. Two additional factors<br />
contribute to the plant’s exceptionally<br />
high performance:<br />
• The press needs only short down-<br />
times for maintenance, thanks to<br />
its heavy duty <strong>de</strong>sign and to the<br />
reliable pressing technology (no<br />
vibration). Typically two weeks<br />
downtime suffice per year for<br />
preventive inspection and<br />
maintenance.<br />
• Mould changes take only a very<br />
short time. The <strong>special</strong> mould<br />
changing <strong>de</strong>vice ‘Hydrofast’<br />
performs a complete change of<br />
the mould within less than one<br />
hour. This is e<strong>special</strong>ly important<br />
for ano<strong>de</strong> producers who supply<br />
ano<strong>de</strong>s of various formats and<br />
sizes to different customers and<br />
who therefore frequently need<br />
to change the mould.<br />
Product quality: An important feature<br />
of hydraulic presses in general, and of<br />
the HPF presses in particular, is the<br />
extreme dimensional accuracy which<br />
they can achieve. Despite the relative-<br />
Parameter Effect<br />
ly large height of the typical ano<strong>de</strong>s<br />
and the corresponding long <strong>de</strong>nsification<br />
stroke of the press plunger,<br />
these presses guarantee a <strong>de</strong>viation<br />
in ano<strong>de</strong>s height of less than ±2 mm.<br />
The <strong>special</strong> HPF pressing principle,<br />
together with the vacuum pressing<br />
technology, provi<strong>de</strong>s optimum <strong>de</strong>nsification<br />
and even <strong>de</strong>nsity distribution<br />
within the ano<strong>de</strong>. Pressing un<strong>de</strong>r<br />
vacuum can be expected to lead to<br />
several advantages such as:<br />
• Higher green <strong>de</strong>nsity of the<br />
ano<strong>de</strong>s<br />
• Higher green strength of the<br />
ano<strong>de</strong>s, which can be pressed<br />
and handled at higher temperatures<br />
than when pressing<br />
without vacuum<br />
• Lower electrical resistance, which<br />
is aggravated by entrapped air<br />
• Less <strong>de</strong>nsity variation in vertical<br />
direction within the ano<strong>de</strong>s.<br />
In general, hydraulic presses can form<br />
ano<strong>de</strong>s at much lower temperatures<br />
than can vibrocompacting (typically<br />
30 to 40 K lower). This again contributes<br />
to a higher strength and dimensional<br />
stability of the green ano<strong>de</strong>s<br />
Charger moving speed Cycle time; homogeneity of mould cavity filling<br />
Charger movement Complete discharge of paste batch into mould cavity<br />
Mould moving speed during filling Cycle time; even cavity filling<br />
Plunger speed (multiple adjustable) Cycle time; paste <strong>de</strong>nsification; <strong>de</strong>nsity distribution<br />
Mould frame movement relative to plunger movement Paste <strong>de</strong>nsification; <strong>de</strong>nsity distribution<br />
Vacuum application (time, duration, final vacuum) Cycle time; paste <strong>de</strong>nsification<br />
Pressing speed(s) Cycle time; paste <strong>de</strong>nsification<br />
Pressure increase speed limitation Cycle time; paste <strong>de</strong>nsification<br />
High pressure holding time, pressure relief Cycle time; paste <strong>de</strong>nsification; ano<strong>de</strong> back expansion<br />
Ano<strong>de</strong> ejection (with or without load; load weight) Cycle time; ano<strong>de</strong> back expansion<br />
Table 2: Press control parameters to be set and/or changed by the operator<br />
42 ALUMINIUM · 1-2/2008
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
(no bulging) and avoids the need for<br />
additional water cooling of the ano<strong>de</strong>s<br />
after forming.<br />
Environmental impact reduction:<br />
The low forming temperature reduces<br />
the environmental impact of ano<strong>de</strong><br />
manufacture in several ways:<br />
• As mentioned above, ano<strong>de</strong>s need<br />
no water cooling, thus saving<br />
direct investment costs and<br />
running costs, but also reducing<br />
water consumption and avoiding<br />
contamination of cooling water<br />
• There is less emission of volatile<br />
pitch components (e<strong>special</strong>ly<br />
PAHs) from the forming area, thus<br />
improving the working environment.<br />
Exhaust connections at all<br />
critical points minimize air pollution<br />
and can be combined with<br />
existing air cleaning systems.<br />
Another remarkable contribution to<br />
environmental impact reduction and<br />
labour comfort is the low noise level<br />
of the MEGA 1600 AV with ≤ 76 dBA.<br />
Summary<br />
A new hydraulic pressing concept for<br />
ano<strong>de</strong>s has been <strong>de</strong>veloped with the<br />
Laeis hydraulic vacuum press MEGA<br />
1600 AV. It is based on state-of-the-art<br />
pressing technology with matching<br />
plant components for paste cooling<br />
and conditioning, dosing and weighing<br />
units as well as for other peripheral<br />
equipment.<br />
This press can produce highest<br />
quality ano<strong>de</strong>s of all sizes required<br />
today, and has an unmatched production<br />
capacity of up to 50 t/h or higher<br />
in a single line. A high plant availability,<br />
together with low maintenance<br />
costs and reduced environmental impact,<br />
make this technology attractive<br />
for ano<strong>de</strong> producers.<br />
References<br />
[1] R. Kremer and R. Lutz: Quality improvement<br />
of shaped refractories by<br />
Visit us at<br />
TMS 2008<br />
Booth #211<br />
mo<strong>de</strong>rn pressing technology; Preprints<br />
49. Internat. Colloquium on Refractories<br />
(2006), 223–226.<br />
[2] R. Lutz: Use of closed loop controls in<br />
hydraulic press forming of ceramic products<br />
to obtain highest dimensional accuracy;<br />
Stahl und Eisen Special, Refractories<br />
in Steelmaking, 47. Internat. Colloquium<br />
on Refractories (2004), 222–224.<br />
[3] W. K. Fischer and M. W. Meier: Advances<br />
in Ano<strong>de</strong> Forming; Light Metals<br />
(1999), ed. C. E. Eckert (TMS, Warrendale,<br />
Pa), 541-546.<br />
[4] K. L. Hulse: Ano<strong>de</strong> Manufacture – Raw<br />
Materials, Formulation and Processing<br />
Parameters, Ph. D. Thesis, R&D Carbon<br />
Ltd., (2000).<br />
[5] A. Kaiser: Hydraulic pressing promises<br />
better ano<strong>de</strong>s, Part I, <strong>Alu</strong>minium 80 (2004)<br />
3, 192-198, Part II: <strong>Alu</strong>minium 80 (2004)<br />
4, 276-281.<br />
Author<br />
Dr. Alfred Kaiser is Manager Business<br />
Development of LAEIS GmbH, based in<br />
Wecker, Luxembourg.<br />
43 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 43
ALUMINIUM SMELTING INDUSTRY<br />
Zero fuel baking – the total heat recovery concept<br />
W. Leisenberg, Butzbach<br />
Fuel costs are going up rapidly,<br />
and to protect the environment<br />
emissions of greenhouse gases<br />
must be as low as possible. The<br />
‘Total Heat Recovery Concept’<br />
will be a big step towards meeting<br />
these requirements. It will<br />
bring the ano<strong>de</strong> plant and also<br />
the electrolysis to a more efficient<br />
state of thermal energy efficiency,<br />
e<strong>special</strong>ly in combination with a<br />
thermal power station.<br />
The greenhouse gas situation<br />
Since the ano<strong>de</strong> is the biggest source<br />
of CO 2 evolved from the smelter, great<br />
efforts have been ma<strong>de</strong> to replace the<br />
carbon ano<strong>de</strong> by non-consumable<br />
electro<strong>de</strong>s, but without significant impact<br />
so far. But is the carbon ano<strong>de</strong><br />
technology really such a bad technology<br />
with regard to the environment?<br />
The most electrical energy world-wi<strong>de</strong><br />
is generated from fossil fuels in thermal<br />
power stations. The energy efficiency<br />
of this conversion process is below 50<br />
percent. By contrast, the chemical efficiency<br />
of the carbon ano<strong>de</strong> in Hall-<br />
Héroult electrolysis is 60 percent. If<br />
we need to use fossil fuel anyway, why<br />
not use it with such a high efficiency as<br />
has the carbon ano<strong>de</strong> in the smelter?<br />
Finally, compared to non-consumable<br />
electro<strong>de</strong>s, the overall greenhouse gas<br />
mass balance for carbon ano<strong>de</strong>s suggests<br />
that no other technology shows<br />
a higher efficiency.<br />
This technology inclu<strong>de</strong>s a most<br />
efficient use of fuel for calcining of the<br />
carbon ano<strong>de</strong>s; and there is a really<br />
consi<strong>de</strong>rable potential left for heat<br />
recovery.<br />
Ano<strong>de</strong> baking heat balance<br />
As shown in Fig. 1, ano<strong>de</strong> baking is<br />
a highly exothermal process. The<br />
quantity of tar pitch fed to the process<br />
represents far more energy than is<br />
nee<strong>de</strong>d to bake the ano<strong>de</strong> [1].<br />
In theory the baking process as<br />
such requires less than 350 MJ/t of<br />
ano<strong>de</strong>. Most of the energy is stored as<br />
heat as the ano<strong>de</strong> reaches 1100°C at<br />
the end of the soaking time. In practice<br />
we also heat up the baking furnace<br />
structure and the packing material, so<br />
the real baking process needs much<br />
more energy as shown in Fig. 2.<br />
Not all of that stored heat can be<br />
recovered, because the ano<strong>de</strong>s usually<br />
are unloa<strong>de</strong>d at a temperature of<br />
about 200°C. Therefore some residual<br />
heat is left in the ano<strong>de</strong>s, in the refractory<br />
and in the packing coke, as<br />
shown in Fig. 3.<br />
Baking furnace heat balance<br />
Today open pit horizontal flue ring<br />
Fig. 1: Ano<strong>de</strong> baking heat balance<br />
Fig. 2: Total stored heat<br />
Fig. 3: Residual heat<br />
furnaces are used for ano<strong>de</strong> baking.<br />
The principle of the ring furnace is<br />
to internally recycle some of the heat<br />
stored in the cooling area. In terms of<br />
heat flow, the ring furnace consists of<br />
two convection heat exchangers with<br />
a firing zone between. In the first heat<br />
exchange process, cold air is blown<br />
into the cooling area and is heated<br />
by hot ano<strong>de</strong>s, packing material and<br />
furnace structure. This air then passes<br />
into the firing zone as preheated<br />
combustion air, becomes flue gas,<br />
and further downstream it transfers<br />
the majority of its heat content to the<br />
cold ano<strong>de</strong>s. Fig. 4 shows the heat<br />
balance of a baking furnace typical<br />
44 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Fig. 4: Baking furnace heat balance<br />
Fig. 5: Improved furnace <strong>de</strong>sign and control<br />
Fig. 6: Baking process with ‘complete pitch burn’<br />
for the situation twenty years ago.<br />
Firstly we can see that little or no<br />
tar pitch burns, so its energy is mostly<br />
lost. The furnace <strong>de</strong>sign was not optimized,<br />
and so the fuel consumption<br />
was as high as 3300 MJ/t of ano<strong>de</strong>. A<br />
great amount of waste heat – 1900 MJ/<br />
t – blows from the cooling area into<br />
the furnace hall. The heat balance of<br />
the furnace is completed by the various<br />
other losses from the furnace.<br />
The end of the 20 th century saw<br />
improvements in furnace <strong>de</strong>sign,<br />
such that impulse firing technology,<br />
and control of both the firing zone and<br />
preheat area became state-of-the-art.<br />
Due to the higher homogeneity of the<br />
pit temperatures, the peak temperature<br />
of the flues could be reduced from<br />
nearly 1300 to less than 1200°C.<br />
This lower peak temperature, together<br />
with lower refractory mass of<br />
the furnace structure, led to a lower<br />
stored heat in the cooling area (Fig. 5)<br />
and finally to lower the fuel consumption,<br />
down to typically 2400 MJ/t [2].<br />
A further big step in reducing of<br />
fuel consumption was the ‘Complete<br />
Pitch Burn Technology’ introduced by<br />
Innovatherm in the last few years [3].<br />
By using practically all of the energy<br />
in the tar pitch, this technology has<br />
reduced fuel consumption dramatically<br />
to a bench mark of 1800 MJ/t<br />
today (Fig. 6).<br />
We see from the Sankey diagram<br />
shown in Fig. 6 that a lot of heat is<br />
still not used. Part of this waste heat<br />
blows from the cooling area into the<br />
furnace hall, creating oppressively<br />
hot ambient temperatures e<strong>special</strong>ly<br />
in hot countries.<br />
The other part leaves the furnace<br />
with the flue gas. Since not all the heat<br />
content of the volatiles can be kept in<br />
the baking process, the waste gas temperature<br />
is about 100°C higher than<br />
with incomplete pitch burn.<br />
Heat recovery<br />
Obviously there is a lot more surplus<br />
heat available from the baking furnace,<br />
so two questions arise: how can<br />
we take that heat from the furnace and<br />
where can we use it?<br />
The answer to the ‘where?’ is: coke<br />
heating in the paste plant is the only<br />
major heat sink in the ano<strong>de</strong> �<br />
45 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
plant. About 200 MJ/t are necessary<br />
to heat the coke to about 150°C, including<br />
some heat for supplementary<br />
equipment. Regarding the ‘how?’: if<br />
we look at a simplified Sankey diagram<br />
for the baking process, including<br />
the fume treatment plant shown<br />
in Fig. 7 we will find that the flue gas<br />
and the waste heat in the cooling area<br />
are the two main heat sources.<br />
A technology to use the heat of the<br />
flue gas in the paste plant has been<br />
proposed by the author earlier [4].<br />
But this concept is hardly accepted<br />
because the paste plant would need<br />
serious modification due to the relatively<br />
low temperature of the flue<br />
gases. So the energy now is <strong>de</strong>leted<br />
in the conditioning tower of the fume<br />
treatment plant (FTP).<br />
The paste plant needs higher gas<br />
temperatures if its technology will<br />
not be changed. As shown in Fig. 5,<br />
the ring furnace recovers some heat<br />
from the cooling area. Another small<br />
part disappears as heat loss due to<br />
radiation, convection and ‘blow-out’<br />
of hot air via leakages, or remains as<br />
residual heat in the ano<strong>de</strong>s, the packing<br />
material and the refractory. The<br />
balance heat of 1200 MJ/t blows into<br />
the furnace hall.<br />
In or<strong>de</strong>r to create an energy link,<br />
the thermal transfer oil for the paste<br />
plant collects the baking furnace<br />
waste heat from the cooling area. This<br />
thermal transfer oil then serves as a<br />
heat supply for the heating screw and<br />
the kneading/mixing plant.<br />
To realize this recovery technology,<br />
firstly one of the two blower ramps<br />
in the cooling area is replaced by an<br />
exhaust ramp. So there is no change<br />
in the number of equipment units on<br />
the furnace or in the investment costs,<br />
as shown in Fig. 8<br />
Further, a second hot air duct, besi<strong>de</strong>s<br />
the flue gas duct, is installed to<br />
collect the hot air from the cooling<br />
areas of all fires and to direct it to a<br />
heat exchanging unit. Here the hot air<br />
gives its energy to the thermal transfer<br />
oil for the paste plant (Fig. 9). The heat<br />
exchange unit is not subject to corrosion<br />
because the hot air from the<br />
cooling area is not contaminated by<br />
any corrosive or acid fumes.<br />
Since the temperature of the air<br />
taken from the cooling area is about<br />
Fig. 7: Heat balance including fume treatment<br />
Fig. 8: Cooling area equipment<br />
400°C, it easily provi<strong>de</strong>s the thermal<br />
oil temperature of 300°C which the<br />
paste plant needs. This concept supplies<br />
all thermal energy required from<br />
the paste plant without changing the<br />
proven paste plant technology. For<br />
start-up operation or to bridge any<br />
temporary lack of heat, a heat generator<br />
is placed in the hot air duct. So<br />
the boiler for the thermal transfer oil<br />
in the paste plant, including its stand<br />
by unit, is eliminated completely. The<br />
overall investment costs are kept the<br />
same.<br />
Of course, the hot air, after passing<br />
the heat exchanger, can be re-used<br />
for other purposes such as for coke<br />
drying or for building heating in cold<br />
countries.<br />
Total heat recovery concept<br />
A complete heat recovery can be realised<br />
in a second step if a thermal<br />
power station is located near to the<br />
smelter.<br />
Every thermal power station heats<br />
water for the boiler to generate steam<br />
for the turbines. The amount of water<br />
required is so large, and the temperature<br />
of the fresh water is so low, that<br />
it acts as an i<strong>de</strong>al heat sink to recover<br />
any remaining heat from the furnace.<br />
Even a portion of the whole amount of<br />
water will suffice to recover all waste<br />
heat of the baking process.<br />
The remaining heat of the hot air<br />
from the cooling area can easily be<br />
extracted by installing a second heat<br />
exchange unit downstream from the<br />
unit for the thermal transfer medium<br />
(Fig. 10).<br />
The water for the power station<br />
can also recover residual heat from<br />
the flue gas. A two-step heat exchange<br />
plant transfers all usable heat to the<br />
water. This cools the flue gas to about<br />
130°C as it enters the fume treatment<br />
46 ALUMINIUM · 1-2/2008
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Fig. 9: Coke heating by hot air from cooling area<br />
Fig. 10: ‘Total Heat Recovery Concept’<br />
plant. A lower flue gas temperature is<br />
un<strong>de</strong>sirable because acid components<br />
would con<strong>de</strong>nse at the <strong>de</strong>w point of<br />
the waste gas. As a si<strong>de</strong> effect, the flue<br />
gas temperature will be kept constant<br />
and so minimise the <strong>de</strong>mand of water<br />
in the conditioning.<br />
If we assume about 90 percent efficient<br />
heat transfer to the boilers in the<br />
power station and in the paste plant,<br />
then each recovered Joule saves 11<br />
percent more fuel at the power station<br />
respectively at the paste plant.<br />
The equivalent-to-fuel heat recovery<br />
then is nearly 1900 MJ/t, which is<br />
more than what the baking furnace<br />
requires as fuel. This means that the<br />
baking process, including all losses, is<br />
virtually fed by tar pitch only and can<br />
be consi<strong>de</strong>red to run at zero fuel. This<br />
concept will set a new benchmark<br />
for the fuel efficiency in aluminium<br />
smelters.<br />
Summary<br />
With the ‘Total Heat Recovery Concept’<br />
technology consi<strong>de</strong>red in this<br />
paper, the fuel efficiency of the ano<strong>de</strong><br />
baking process can be brought very<br />
close to the theoretical limit of running<br />
at zero fuel. All equipment which<br />
is necessary for this concept is proven<br />
and available today.<br />
References<br />
[1] B. J. Racunas: Ano<strong>de</strong> baking furnace<br />
thermal balance, Light Metals 1980, ed.<br />
H.O. Bohner (TMS, Warrendale, Pa).<br />
[2] Alcan/AP, Inst. Paul Heroult: Ano<strong>de</strong>s<br />
Baking, AN 3 5 CAEN V3, 2004.<br />
[3] W. Leisenberg: Firing and control technology<br />
for complete pitch burn and its<br />
consequences for ano<strong>de</strong> quality, energy<br />
efficiency and fume treatment plant, 9 th<br />
Intl Conf. on Non Ferrous Metals, July 8-9,<br />
2005, Pune.<br />
[4] D. Maiwald and W. Leisenberg: The<br />
<strong>de</strong>velopment of ano<strong>de</strong> baking technology<br />
from past to future, Light Metals 2007, ed.<br />
M. Sørlie (TMS, Warrendale, Pa), pp. 947-<br />
952.<br />
Author<br />
Prof. Dr. Wolfgang Leisenberg is Director<br />
of innovatherm Prof. Dr. Leisenberg<br />
GmbH u. Co. KG, Butzbach, Germany.<br />
47 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
Best available technology<br />
for the fume treatment of ano<strong>de</strong> production plants<br />
M. Hagen, B. Schricker; Goldkronach<br />
The new IPPC regulation [1] as<br />
well as local legislation force aluminium<br />
manufacturers to improve<br />
their air emission control systems.<br />
Furthermore a critical neighbourhood<br />
puts pressure on plant managers<br />
to think about the future of<br />
their plant.<br />
<strong>Alu</strong>minium production plants have<br />
several sources of emissions. Dust<br />
emissions are trapped using bag<br />
house filters for many years. For the<br />
additional adsorption of HF, recycled<br />
from the electrolysis cells, these filters<br />
have been equipped with alumina<br />
injection. All these systems are stateof-the-art<br />
and are accepted as ‘best<br />
available technology’.<br />
Based on this favourable experience,<br />
companies often copied these<br />
fume treatment systems for the abatement<br />
of particulate pitch and tar fumes<br />
coming from the baking furnace and<br />
from paste production. But the pitch<br />
and tar at high temperatures also generates<br />
other volatile emissions, which<br />
potline filters cannot treat. These fumes<br />
contain a mix of odorous and carcinogenic<br />
substances, known as polycyclic<br />
aromatic hydrocarbons (PAH).<br />
For these volatile compounds, as<br />
well as for con<strong>de</strong>nsed particulates, a<br />
fume treatment system based on regenerative<br />
thermal oxidation (RTO) is<br />
the ‘best available technology’ according<br />
to the IPPC. The aim of LTB was to<br />
create an abatement system, capable<br />
of fulfilling the emission control levels<br />
even in the long term. During three<br />
years of testing with a small plant and<br />
of running a full scale pilot unit LTB<br />
created a specific ‘Carbon <strong>de</strong>sign’-<br />
RTO. In or<strong>de</strong>r to explain the <strong>de</strong>tails<br />
of this <strong>special</strong> <strong>de</strong>sign this article will<br />
again present the basic principles of<br />
RTO.<br />
Type of emissions<br />
In or<strong>de</strong>r to <strong>de</strong>sign an appropriate fume<br />
treatment system we need to know the<br />
type and amount of pollutants. The<br />
two main processes which generate<br />
air emissions from ano<strong>de</strong> production<br />
plants are: paste production and baking.<br />
Even if the rough numbers seem<br />
to be equal, there are huge differences<br />
in emissions from paste plants compared<br />
to baking furnaces. The reason<br />
Fig. 1: Composition of PAH emission from a baking furnace (example)<br />
is mainly the different temperature<br />
at which the fumes are generated.<br />
The most important factors for paste<br />
plants are:<br />
• Type of mixer<br />
• Type of cooler and amount of<br />
cooling water/temperature<br />
• Mass of produced paste<br />
• Additional connected sources.<br />
The most important factors for baking<br />
furnaces are:<br />
• Type of furnace (open or closed<br />
type baking)<br />
• Production cycle and output<br />
• Type of fuel and firing system<br />
• Raw materials for ano<strong>de</strong>s (e. g. HF<br />
due to re-use of butts; SOx due to<br />
sulphur content 0.5 to 4%).<br />
Table 1 (next page) shows the range of<br />
possible emissions at furnaces without<br />
a fume treatment.<br />
In particular the polycyclic aromatic<br />
hydrocarbons (PAHs) are critical target<br />
substances for the <strong>de</strong>sign of a RTO,<br />
e<strong>special</strong>ly those PAHs which consist of<br />
more than two benzoic rings.<br />
Depending on the temperature<br />
they can appear as volatile gases or<br />
as con<strong>de</strong>nsed particles. Fig. 1 shows<br />
an example analysis of PAH- �<br />
48 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
open type<br />
furnace<br />
containing flue gas containing various<br />
amounts of particulate and gaseous<br />
matter (PAH listed with increasing<br />
boiling point from left to right).<br />
A typical example in the middle of<br />
the PAH list is benzo(a)pyrene, which<br />
has five rings, a molecular weight of<br />
252 and a boiling point of 496°C. As<br />
Fig. 1 shows, the substances with a<br />
lower molecular weight are mostly<br />
gaseous un<strong>de</strong>r the conditions of a furnace.<br />
Therefore a large part of them<br />
will burn already in the furnace (e<strong>special</strong>ly<br />
in the open type furnace). With<br />
increasing boiling temperature, most<br />
of the PAH appear solid or con<strong>de</strong>nsed<br />
(Fig. 1).<br />
Historical background<br />
and state-of-the-art technology<br />
To trap particle emissions, electrostatic<br />
precipitators (ESP) have often<br />
been used. To improve the efficiency<br />
of these ESP in trapping con<strong>de</strong>nsed<br />
tars, lots of them have been equipped<br />
with an upstream cooler. Based on<br />
stricter limits for the total carbon emissions<br />
imposed during the late 1980s,<br />
new systems have been <strong>de</strong>veloped [3].<br />
Their <strong>de</strong>sign was similar to the fume<br />
close type<br />
furnace<br />
Ano<strong>de</strong> specific<br />
flue gas volume<br />
m3 /t 5,000 3,500<br />
CO mg/Nm3 < 1,200 < 1,500<br />
Total carbon mg/Nm3 100-300 < 1000<br />
Tar/con<strong>de</strong>nsates mg/Nm3 200-400 800-1,200<br />
PAH mg/Nm3 20-200 40-500<br />
Soot/dust mg/Nm3 100-200 50-100<br />
SOx mg/Nm3 100-800 100-800<br />
HF mg/Nm3 5-300 5-300<br />
Tab. 1: Typical gross emissions during ano<strong>de</strong> baking [1]<br />
Fig. 3 and 4: Redundant prefilter system<br />
Fig. 2: LTB RTO test plant [2]<br />
treatment centres of the electrolysis<br />
pots, using a dry scrubbing process<br />
with alumina as an ab- and adsorbent<br />
to eliminate the particulate pollutants.<br />
Due to complaints from neighbours<br />
and to stricter emission limits,<br />
in the 1990s volatile compounds and<br />
odour started to get more and more<br />
critical attention. In Europe an increasing<br />
number of countries reduced<br />
the legal limits for polycyclic aromatic<br />
hydrocarbons (PAH) e<strong>special</strong>ly<br />
benzo(a)pyrene, which is supposed<br />
to be carcinogenic. The only known<br />
technology to reduce these PAH, as<br />
well as total carbon, below the required<br />
limits is a thermal oxidation.<br />
I<strong>de</strong>ally this thermal oxidation plant<br />
is equipped with a regenerative heat<br />
exchanger so as to recover most of the<br />
energy the process requires.<br />
Already in 1994 the German Environmental<br />
Protection Agency started<br />
a test plant in Germany to reduce PAH<br />
emissions downstream of an electro-<br />
static filter [4]. In the late 1990s a<br />
German company entered the market<br />
with an RTO system. Two plants were<br />
built but had huge problems due to<br />
clogging of the valve system.<br />
Since 2005 a combination of prefilter,<br />
RTO and packed bed filter (for HF<br />
adsorption) treats the emissions of an<br />
open type furnace in the Netherlands.<br />
In 2004 LTB started to operate a<br />
test plant in the bypass of a closed<br />
type baking furnace. Closed furnaces<br />
generally produce very concentrated<br />
emissions compared to open type furnaces<br />
(see Table 1).<br />
The target of the test runs was to<br />
check the basic cleaning efficiency<br />
and to find an appropriate <strong>de</strong>sign for<br />
the valve system. As the valve system<br />
is an essential component of a low<br />
emission system, it has to work reliably<br />
even un<strong>de</strong>r the heavy pollutant<br />
load coming from a baking furnace.<br />
The tests showed that the <strong>de</strong>struction<br />
of total carbon in the RTO is not<br />
a problem at sufficient burning tem-<br />
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SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Fig. 5: 4-chamber RTO for continuous burn-out with separate burn-out fan<br />
peratures (Fig. 3). But the tests also<br />
showed that the almost complete<br />
<strong>de</strong>struction of the PAH is a very ambitious<br />
task. The test plant reached<br />
a cleaning efficiency of single PAH<br />
compounds between 88 and 98%, <strong>de</strong>pending<br />
on the concentration and the<br />
type of PAH. But a pre-cleaning filter<br />
is necessary to increase the overall efficiency<br />
above 97%.<br />
This can be done, for example,<br />
with a fixed bed filter which collects<br />
the con<strong>de</strong>nsed PAH fraction. As this<br />
filter will accumulate con<strong>de</strong>nsables<br />
and tar, it has to be cleaned periodically.<br />
Therefore two redundant fixed<br />
bed filters have to be installed to enable<br />
continuous operation by cleaning<br />
the fume gases in one filter during purification<br />
of the other prefilter (Figs.<br />
3 and 4). An alternative filter could<br />
be an electrostatic precipitator (ESP),<br />
which often already exists at ano<strong>de</strong><br />
production plants.<br />
An opposite approach is to increase<br />
the temperature of the flue gases entering<br />
the RTO by changing the burn-<br />
ing curve or even by adding a heater.<br />
As tests from LTB prove, this will only<br />
lead to increased energy consumption<br />
but not to a significant reduction of<br />
the PAH load. The reason is the very<br />
high boiling temperature of many<br />
PAHs which usually is much hotter<br />
than the flue gas temperature of the<br />
furnace, and so cannot be reached<br />
with only a mo<strong>de</strong>rate increase of the<br />
flue gas temperature.<br />
For this <strong>special</strong> kind of flue gas<br />
composition (Fig. 1) LTB therefore<br />
has focused on the <strong>de</strong>velopment of<br />
a highly efficient pre-filter system in<br />
combination with an optimized burnout<br />
mo<strong>de</strong>.<br />
Current LTB <strong>de</strong>velopments<br />
During operation of a conventional<br />
RTO-plant, tar and other high-boiling<br />
hydrocarbons, tend to <strong>de</strong>posit and accumulate<br />
on the inner valvebox walls<br />
and on the inlet surface of the ceramic<br />
heat exchanger blocks (Fig. 6). This<br />
con<strong>de</strong>nsate compromises cleaning<br />
Fig. 8: Valve box <strong>de</strong>sign Fig. 9: RTO during erection<br />
Fig. 6: Ceramics before bake out<br />
Fig. 7: Ceramics after bake out<br />
efficiency in two ways: the pressure<br />
drop of the plant increases, and the<br />
higher gas velocity will partially strip<br />
off precipitated tar from the valveboxwalls<br />
so that part of the PAH fraction<br />
may get back into the clean gas.<br />
In or<strong>de</strong>r to keep the cleaning efficiency<br />
at a high level, a periodical<br />
cleaning of the tar coated parts<br />
is therefore necessary, the so called<br />
burn-out mo<strong>de</strong>.<br />
In the burn-out mo<strong>de</strong>, a separate<br />
burn-out fan sucks hot burning chamber<br />
gases down through the ceramics.<br />
The con<strong>de</strong>nsates, as well as inclu<strong>de</strong>d<br />
un-burnable particles, start to liquefy<br />
and to drop into the bottom discharge<br />
cone (drop-out mo<strong>de</strong>). This con<strong>de</strong>nsed<br />
tar will inclu<strong>de</strong> around 10% ash and<br />
other inert compounds. So most of the<br />
non-combustibles, dust and ash will be<br />
removed from the system. By further<br />
increasing the temperature up �<br />
51 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 51
ALUMINIUM SMELTING INDUSTRY<br />
Fig. 10: RTO with collecting ductwork and prefilter Fig. 11: LTB HF absorbers<br />
to a maximum of 550°C, it is possible<br />
to gasify all con<strong>de</strong>nsed hydrocarbons.<br />
These gases have a high calorific value<br />
and they can therefore be re-used as a<br />
fuel in the burning chamber. For this<br />
purpose <strong>special</strong> tar burners are installed.<br />
The result is a clean surface of<br />
the heat exchange blocks (Fig. 7).<br />
In any case, an upward airflow<br />
<strong>de</strong>sign from the bottom of the ceramics<br />
up to the burning chamber should<br />
be avoi<strong>de</strong>d because this would only<br />
lead to a complete infiltration of the<br />
ceramic heat exchanger media.<br />
At very high tar loads in the flue gas,<br />
it becomes necessary to run the burnout<br />
mo<strong>de</strong> continuously and in<strong>de</strong>pen<strong>de</strong>ntly<br />
from the normal three-chamber<br />
operation. In this <strong>special</strong> case a fourth<br />
chamber is ad<strong>de</strong>d to the RTO (Fig. 5).<br />
This allows a normal three-chamber<br />
operation while there is always one<br />
chamber in burn-out mo<strong>de</strong>.<br />
In or<strong>de</strong>r to reach the required low<br />
emission limits, the valves of a RTO are<br />
the most important parts. If they are<br />
not tight enough, the resulting leakage<br />
will allow some flue gases to pass<br />
directly to the clean gas duct without<br />
passing the burning chamber. For this<br />
difficult application the standard <strong>de</strong>sign<br />
of the valve system was adapted<br />
by LTB. E<strong>special</strong>ly during the<br />
drop-out mo<strong>de</strong>, con<strong>de</strong>nsates<br />
drop<br />
down<br />
Fig. 12: Layout with furnace<br />
from the ceramic bed into the valve<br />
box. In or<strong>de</strong>r to avoid clogging of the<br />
valves, the complete valve-box has<br />
been re-<strong>de</strong>signed (see Figs. 8 and 9).<br />
The valves have been placed outsi<strong>de</strong><br />
the dropping area so as to keep<br />
them and the sealing clean. All dropping<br />
con<strong>de</strong>nsates are collected in the<br />
heated cone below, from where they<br />
can be discharged easily.<br />
However, normal ‘poppet’ valves<br />
or rotary systems would fail for technical<br />
<strong>de</strong>sign reasons, e<strong>special</strong>ly at the<br />
influence of high temperatures caused<br />
by the burn-out mo<strong>de</strong>.<br />
Experience and results<br />
In the experience of LTB, the RTObased<br />
type of flue gas cleaning is the<br />
only system which can reach the<br />
required low limits for volatile compounds<br />
un<strong>de</strong>r the hard conditions at<br />
baking furnaces. This experience is<br />
also used in green ano<strong>de</strong> plants which<br />
run modified versions of the RTO.<br />
With the <strong>special</strong> carbon-<strong>de</strong>sign of the<br />
RTO, LTB achieved more than 97%<br />
cleaning efficiency for PAH and more<br />
than 98% related to benzo-a-pyrene,<br />
respectively.<br />
Nevertheless, the required<br />
PAH<br />
limits are<br />
quite low<br />
and hard<br />
to reach.<br />
Therefore<br />
additional,<br />
new methods<br />
of prefiltering<br />
and post-treating<br />
the clean gases are being<br />
tested to further reduce<br />
the emissions. The results will be<br />
presented later in a separate article.<br />
As a final stage of the plant, a HF treatment<br />
system could be ad<strong>de</strong>d (Fig. 12).<br />
As wet scrubbing systems would create<br />
waste water from this application,<br />
a dry packed bed scrubber is preferred.<br />
This technology was <strong>de</strong>veloped<br />
by LTB in the 1980s and is used<br />
in several installations of the ceramic<br />
industry (Fig. 11). Insi<strong>de</strong> the casing<br />
there are several casca<strong>de</strong>s, filled with<br />
grainy limestone. These absorption<br />
zones ensure a good contact of the HF<br />
with the absorbent, which will react<br />
spontaneously to fluori<strong>de</strong> (CaF 2 ).<br />
References<br />
[1] Reference Document on Best Available<br />
Technology in the non ferrous metals industry,<br />
May 2000, European IPPC Bureau,<br />
Sevilla http://eippcb.irc.es.<br />
[2] M. Hagen: New requirements and solutions<br />
for the fume treatment at paste mixing<br />
and ano<strong>de</strong> baking plants; Light Metals<br />
2006, ed. T. J. Galloway (TMS, Warrendale,<br />
Pa), 615-619.<br />
[3] Procedair leaflet air pollution control<br />
12/99.<br />
[4] W. Hammer et al.: UBA-FB AP 2058;<br />
Vermin<strong>de</strong>rung von PAH-Emissionen<br />
durch Errichtung und Betrieb einer thermischen<br />
Nachverbrennung mit Wärmerückgewinnung<br />
für Ringöfen zur Herstellung<br />
von Elektrographit; SGL Carbon<br />
GmbH; August 1994.<br />
[5] M. Hagen, W. Hilgert and R. Skiba:<br />
Results of operating a RTO based fume<br />
treatment system at a baking furnace; Light<br />
Metals 2007, ed. M. Sørlie (TMS, Warrendale,<br />
Pa), 977-980.<br />
Authors<br />
Dipl.- Ing. (FH) Matthias Hagen has been<br />
working for LTB for 20 years and is responsible<br />
for all sales.<br />
Dr.- Ing. Bernd Schricker at LTB is responsible<br />
for process <strong>de</strong>sign and new <strong>de</strong>velopments.<br />
52 ALUMINIUM · 1-2/2008
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
53 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 53
ALUMINIUM SMELTING INDUSTRY<br />
New generation<br />
of FLSmidth Möller direct pot feeding system<br />
C. Duwe, Pinneberg; T. Letz, Dubai<br />
<strong>Alu</strong>minium has become more important<br />
for many industries and branches<br />
in the last 20 years. Primary aluminium<br />
is produced in so-called electrolytic<br />
cells in aluminium smelter<br />
potlines. In the past, large pot room<br />
cranes fed these electrolytic cells with<br />
the following disadvantages:<br />
• Non-continuous feeding of the<br />
electrolytic cells<br />
• Dust emission when refilling the<br />
alumina bunkers on the pots<br />
• Significant loss of alumina during<br />
filling<br />
• Consi<strong>de</strong>rable crane capacity<br />
nee<strong>de</strong>d<br />
• Extra man-power nee<strong>de</strong>d<br />
• Fluctuating electrolyte composition<br />
causes polluting ano<strong>de</strong> effects<br />
• Ano<strong>de</strong> effects reduce the efficiency<br />
of the smelting process<br />
• High investment and maintenance<br />
costs for the potroom cranes.<br />
Because of this, Möller <strong>de</strong>veloped a<br />
direct pot feeding system.<br />
General <strong>de</strong>scription<br />
The secondary oxi<strong>de</strong> (fluorinated alumina)<br />
from the gas treatment centres<br />
(GTC) is stored in silos near the GTC.<br />
This fluorinated alumina is then taken<br />
from the silos and transported di-<br />
rectly by the direct<br />
pot feeding system<br />
to each of the electrolytic<br />
cells. This<br />
transport system<br />
is pneumatic and it<br />
continuously feeds<br />
the fluorinated<br />
alumina to each<br />
of the electrolytic<br />
cells. The direct<br />
pot feeding system<br />
works in<strong>de</strong>pen<strong>de</strong>ntly of the potroom<br />
cranes; it is fully automatic and absolutely<br />
tight. This <strong>de</strong>sign minimises<br />
maintenance work as well as the<br />
quantity of spare parts nee<strong>de</strong>d.<br />
Functional <strong>de</strong>scription<br />
The new generation of Möller direct<br />
pot feeding (DPF) is no longer a <strong>de</strong>nse<br />
phase conveying system with pressure<br />
vessel for the long distance transport<br />
combined with super feeding system<br />
pipe air sli<strong>de</strong> for conveying to each<br />
of the electrolytic cells. The new DPF<br />
system consists of 100 percent Möller<br />
fluidflow (MF) pipe air sli<strong>de</strong>s DN 100<br />
– 300 to avoid scaling-effects, attrition<br />
(generation of fines) and segregation.<br />
The fluorinated alumina is taken<br />
from the silo at the gas treatment<br />
Fig. 2: Fluorinated alumina silo, Möller fluidflow (MF) pipe air sli<strong>de</strong> to potroom wall, main<br />
intermediate bin, fluidflow pipe air sli<strong>de</strong> along the potroom<br />
Fig. 1: Process flow diagram for the new generation of Möller<br />
direct pot feeding system<br />
centre and transported to the main<br />
intermediate bins, normally one main<br />
intermediate bin for each half of a pot<br />
room.<br />
More MF sli<strong>de</strong> pipes transport<br />
the alumina to the main intermediate<br />
bins (near the potroom walls) as well<br />
as along the two potroom walls. The<br />
main MF pipe air sli<strong>de</strong> DN 300 along<br />
the potroom feeds distribution bins.<br />
Each of these bins feeds two electrolysis<br />
cells via fluidflow super feeding<br />
system pipes DN 100.<br />
All necessary venting domes are<br />
connected with the gas duct.<br />
The fluidflow DPF system works<br />
fully automatically and is more or<br />
less 100 percent filled with alumina<br />
all the time.<br />
Customers often have different requirements<br />
as regards access to crust<br />
breakers and to dosing <strong>de</strong>vices, and the<br />
options for removing alumina ore bunkers<br />
during potline operation. These<br />
requirements influence the final <strong>de</strong>sign<br />
of the MF super feeding system pipe<br />
DN 100 on top of the electrolyte cell.<br />
When the bunker of an electrolysis<br />
cell is full, the bulk material cone<br />
Fig. 3: Möller distribution bin<br />
54 ALUMINIUM · 1-2/2008<br />
Illustrations: FLSmidth Möller
ALUMINIUM SPECIALSMELTING<br />
INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Fig. 4: Various <strong>de</strong>signs of MF super feeding system (SFS)<br />
pipe DN 100 on top of the electrolysis cell<br />
level blocks the filling spout discharge<br />
opening of the MF air sli<strong>de</strong> pipe, and<br />
so the flow of alumina stops automatically.<br />
As fluorinated alumina is<br />
removed from the ore bunker of the<br />
electrolytic cell, the level drops and<br />
the pneumatic transport starts again<br />
automatically, ensuring a constant<br />
and reliable mass feed rate to the pots.<br />
Fluidising of the fluorinated alumina<br />
insi<strong>de</strong> the MF air sli<strong>de</strong> pipe works<br />
permanently to ensure a constant<br />
bulk <strong>de</strong>nsity.<br />
The self-closing filling<br />
spout due to the material<br />
cone level in the ore<br />
bunker of an electrolytic<br />
cell allows a self-regulating<br />
and continuous refilling<br />
of the ore bunkers<br />
during operation of the<br />
smelting plant. The selfclosed<br />
filling spout and<br />
the filling process of the<br />
ore bunker are shown in<br />
Fig. 6 (see next page).<br />
Furthermore, the system<br />
needs no pressure-tight sealing of<br />
the electrolysis cell thanks to the low<br />
(over) pressure in the<br />
MF air sli<strong>de</strong> pipe.<br />
The main advantages<br />
of the new generation<br />
of MF direct pot<br />
feeding system are:<br />
• Self-regulating and<br />
continuous feeding of<br />
ore bunkers<br />
• Absolutely dust-free<br />
operation<br />
• No generation of fine particles<br />
• No segregation<br />
• No scaling<br />
• Lowest possible (over) pressure<br />
• No pressure-tight sealing of the<br />
electrolyte cell<br />
• Minimized energy consumption<br />
• Minimized maintenance work.<br />
The fluidisation air for the MF pipe is<br />
supplied by rotary piston blowers. The<br />
fluidisation air for the MF super feeding<br />
system on top of the electrolysis<br />
cells comes from frequency-controlled<br />
rotary piston blowers in or<strong>de</strong>r to<br />
reduce the energy consumption down<br />
to that nee<strong>de</strong>d for the air actually �<br />
Fig. 5: SFS pipe DN 100 on top of the electrolysis cell<br />
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Fig. 6: Self-closed filling spout and filling process of the ore bunker<br />
Technical Data (example)<br />
Location of erection: Russia<br />
Altitu<strong>de</strong> of plant location: 367 m above sea level<br />
Ambient temperature: min. -50°C, max. 36°C<br />
Conveyed material: Al 2 O 3 (fluorinated alumina)<br />
Bulk <strong>de</strong>nsity: 0.95 – 1,05 t/m 3<br />
Particle size distribution: 100% < 200 μm<br />
90% < 125 μm<br />
up to 15% < 45 μm<br />
Material temperature: 30°C to 60°C<br />
Moisture content: < 0,5 weight % moisture content<br />
(during summer months < 0,6 weight %)<br />
Material characteristics: free flowing, not adhesive,<br />
fluidisable with 1-2 m 3 /min/m 3<br />
Number of potlines: 2<br />
Number of potrooms: 4<br />
Number of CAD units: 4<br />
Number of cells: 672 (4 CAD with 168 cells)<br />
Design conveying capacity: 250 kg/h (each cell)<br />
Fluidisation air for<br />
fluidflow:<br />
Fluidisation air for<br />
SFS pipe air sli<strong>de</strong>s:<br />
4 x 1 group of 3 blowers (2 duty, 1 stand-by)<br />
frequency controlled<br />
4 x 1 group of 3 blowers (2 duty, 1 stand-by)<br />
frequency controlled<br />
Metal treatment update<br />
B. Maltais, D. Privé and M.-A. Thibault; Chicoutimi<br />
At the TMS annual conference in<br />
2002, an interesting and timely<br />
paper (A Technical Perspective on<br />
Molten <strong>Alu</strong>minium Processing)<br />
was presented, in which the author<br />
<strong>de</strong>scribed the quality requirements<br />
for aluminium and its alloys. In<br />
particular, he stated that only<br />
“step-wise improvements to quality<br />
/ productivity / capacity are anticipated”.<br />
During the last six years<br />
following this presentation, there<br />
has in<strong>de</strong>ed been a “step-wise” improvement<br />
in metal treatment.<br />
For example, once metal is siphoned<br />
from pots in the pot room, then the<br />
used. The technical <strong>de</strong>sign data and requirements<br />
for direct pot feeding systems tend to be very similar<br />
but vary <strong>de</strong>pending on the local conditions. The<br />
data below are from a smelter plant in Siberia.<br />
Conclusion<br />
The new generation of Möller fluidflow direct pot<br />
feeding system has been or<strong>de</strong>red for Dubai potline<br />
6b (40 electrolysis cells), Hormozal Smelter (228<br />
electrolyte cells) as well as for Taishet Smelter (672<br />
electrolyte cells) and Boguchansky Smelter (672<br />
electrolyte cells).<br />
This system is <strong>de</strong>signed to ensure the most constant<br />
and reliable feed possible from the ore bunkers<br />
into the electrolysis cell.<br />
Lowest possible conveying velocities preserve the<br />
particle size distribution and the flow ability of the<br />
secondary alumina and so avoiding scaling effects.<br />
This most competitive system is superior also by<br />
minimizing wear and maintenance as well as energy<br />
consumption and last but not least by high operating<br />
reliability.<br />
The successful story of the company’s direct pot<br />
feeding will continue with this new technology,<br />
started at Hamburger <strong>Alu</strong>minium Werk in 1997 and<br />
at <strong>Alu</strong>minij Mostar in 2001.<br />
Authors<br />
prevention of potline bath carry-over<br />
is an ongoing battle. A new <strong>de</strong>tection<br />
method was presented at the recent<br />
Australian Cast House Conference, in<br />
which the presence of bath is automatically<br />
signalled thus alerting the<br />
operators to take preventive action.<br />
Automated skimmers are being installed<br />
in many plants to ensure that<br />
any bath carry over is removed prior<br />
to transport to the casthouse or to the<br />
treatment of aluminium in crucible<br />
(TAC) station, for which several new<br />
<strong>de</strong>signs have been recently implemented.<br />
TAC stations eliminate the<br />
need for sodium removal downstream<br />
in the cast house.<br />
Dipl.-Ing. Carsten Duwe is Head of Technical Department<br />
of FLSmidth Möller, based in Pinneberg, Germany.<br />
Dipl.-Ing. Timo Letz is Senior Engineer Sales and Project<br />
Department of FLSmidth Middle East, Dubai.<br />
More and more plants are turning to<br />
siphoning from the pot crucibles into<br />
the casting furnaces. This approach<br />
is particularly recommen<strong>de</strong>d when a<br />
new furnace is being installed so that<br />
the <strong>de</strong>sign criteria can be easily met.<br />
In ol<strong>de</strong>r plants, there are often height<br />
limitations or restrictions for access<br />
into the furnace for the siphon tube.<br />
Siphoning reduces metal turbulence<br />
and hence minimizes dross generation.<br />
To meet the ongoing requirement<br />
to reduce chlorine gas in plants, the<br />
use of either manual additions of salts<br />
in the casting furnaces or automated<br />
rotary flux injectors was <strong>de</strong>veloped.<br />
56 ALUMINIUM · 1-2/2008
Illustrations: STAS<br />
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Fig. 1: TAC and automatic skimming unit Fig. 2: Efficiencies observed with use of TAC<br />
It is now clearly <strong>de</strong>monstrated and<br />
well established that alkali and inclusion<br />
removal is possible without using<br />
chlorine gas. The salts used for this<br />
application contain magnesium and<br />
potassium chlori<strong>de</strong> with compositions<br />
using less magnesium chlori<strong>de</strong><br />
yet attaining equivalent removal efficiencies.<br />
In a continuing effort to reduce<br />
chlorine usage, new procedures have<br />
shown that additions of chlorine to<br />
a limited number of rotors in a multi-stage<br />
<strong>de</strong>gasser can be more effective<br />
in reducing inclusions. Moreover,<br />
chlorine usage can be completely<br />
eliminated from <strong>de</strong>gassers when salt<br />
additions are ma<strong>de</strong> to optimize inclusion<br />
removal.<br />
Technologies for metal treatment<br />
Automatic skimming machine: Most<br />
producers in the past removed bath<br />
material manually, exposing the operators<br />
to safety and hygiene risks<br />
while still not efficiently removing<br />
bath. Now, automatic skimming machines<br />
are available on the market,<br />
adapted to specific customer needs,<br />
and to the particular transport mo<strong>de</strong>s<br />
in the plant. Many new <strong>de</strong>signs now<br />
available are equipped with a tool e<strong>special</strong>ly<br />
<strong>de</strong>signed to remove the maximum<br />
of solid bath and dross from the<br />
metal surface. In fact, the skimming<br />
efficiency of this machine can be up<br />
to 85 percent dross / bath removal on<br />
a consistent basis. Moreover, the automatic<br />
skimming machine does not<br />
require an operator.<br />
Treatment of aluminium in a crucible:<br />
The TAC technology injects of<br />
aluminium fluori<strong>de</strong> directly into the<br />
crucible to effectively remove the alkali<br />
and alkaline earth metals from<br />
molten aluminium without using<br />
chlorine gas.<br />
Prior to the TAC operation, the<br />
bath material has to be removed. An<br />
automatic skimming machine can be<br />
integrated with the TAC station to remove<br />
this bath material, and can also<br />
reduce labour costs and safety and<br />
hygiene problems. If required, the<br />
skimmer can be used again to remove<br />
dross after the TAC operation.<br />
The TAC technology can efficiently<br />
achieve a concentration of sodium<br />
after treatment as low as few ppm<br />
within a treatment time between 5<br />
and 10 minutes, from an initial value<br />
over 100 ppm.<br />
One of the main advantages of the<br />
TAC is that the flux material (aluminium<br />
fluori<strong>de</strong>) is readily available<br />
in the smelter and it can be recycled<br />
to the pots when the crucible walls<br />
are cleaned with a crucible cleaning<br />
machine. Smelter gra<strong>de</strong> AlF3 is suitable.<br />
Typically, 1 kg of flux per tonne<br />
of aluminium is used.<br />
Brief <strong>de</strong>scription of the equipment:<br />
Figure 1 shows an example of TAC<br />
installations in mo<strong>de</strong>rn smelters. The<br />
rotation of the TAC agitator is powered<br />
by an electric motor coupled to<br />
a gearbox. The rotation speed is in the<br />
range of 100 to 200 rpm. The complete<br />
equipment and its installation<br />
are in accordance with EC standard<br />
to ensure a high level of safety for the<br />
operators.<br />
Advantages of the TAC-automatic<br />
skimming equipment: no chlorine<br />
is used; pot room crucible used; extremely<br />
rapid (less than 10 minutes);<br />
automatic, PLC operation; integrated<br />
dust collector system; low operating<br />
cost.<br />
�<br />
57 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
Fig. 3: Rotary injector Fig. 4: Alcan compact <strong>de</strong>gasser<br />
Rotary fluxing technologies (e. g. RFI/<br />
RGI): In several plants, furnace fluxing<br />
is still used to meet product requirements<br />
with respect to dissolved<br />
alkalis (lithium, sodium, calcium),<br />
non-metallic inclusions and hydrogen.<br />
Furnace fluxing has been traditionally<br />
done either manually with a<br />
salt mix or else using static lances with<br />
a mixture of chlorine / nitrogen gases.<br />
These processes have been progressively<br />
replaced by rotary injectors using<br />
chlorine gas (RGI) or salt mixtures<br />
(RFI).<br />
Alkalines are removed significantly<br />
faster with the RFI / RGI rotary<br />
equipment in comparison with lance<br />
fluxing. The RGI still uses a mixture of<br />
chlorine / nitrogen, but it uses much<br />
less chlorine than does conventional<br />
lance fluxing. On the other hand, the<br />
RFI completely replaces chlorine by<br />
salts containing magnesium and potassium<br />
chlori<strong>de</strong>.<br />
Fig. 5: Conventional versus sealed ACD<br />
58<br />
Rotary salt fluxing processes help<br />
achieve high removal efficiencies<br />
within limited process times. However,<br />
the main gain is in terms of environment<br />
and safety issues.<br />
Brief <strong>de</strong>scription of the equipment:<br />
The injection module is composed of a<br />
graphite rotor and shaft, a driving system<br />
and a flux fee<strong>de</strong>r. The flux fee<strong>de</strong>r<br />
contains and doses the flux required<br />
for one treatment. The dosing system<br />
allows for the precise distribution of<br />
the flux during a treatment.<br />
The injection module must be<br />
placed at a very specific location into<br />
molten metal. Since each plant and<br />
even each furnace is different, several<br />
<strong>de</strong>signs have been <strong>de</strong>veloped to meet<br />
customer requirements. Some equipment<br />
can be used to treat one furnace<br />
only, while others can treat two furnaces<br />
in sequence. Mobile units have<br />
also been <strong>de</strong>veloped to process several<br />
furnaces.<br />
Advantages of the RFI equipment:<br />
reduces alkalis, inclusions, HCl and<br />
dust emissions; ensures temperature<br />
and alloy homogeneity by stirring action;<br />
eliminates the use of chlorine gas<br />
for furnace fluxing.<br />
Degassing technologies (e. g. ACD):<br />
The aluminium compact <strong>de</strong>gasser<br />
(ACD) is a multi-stage, in-line <strong>de</strong>gassing<br />
machine that treats molten aluminium<br />
directly in the trough. Several<br />
papers have <strong>de</strong>scribed this technology<br />
in the past ten years.<br />
Brief <strong>de</strong>scription of the equipment:<br />
The ACD is composed of three main<br />
components:<br />
• One or more driving modules:<br />
drive assembly for the graphite<br />
rotors used to inject and disperse<br />
the treatment gases (mixture of<br />
chlorine/argon or argon only)<br />
• A sealed hood: this supports<br />
the drive module(s), encloses the<br />
fumes generated during treatment,<br />
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and shields the metal from ambient<br />
conditions<br />
• A retraction system: lowers and raises the<br />
hood and maintains it at the position<br />
required for maintenance operations.<br />
Control is automatic through the use of a<br />
PLC.<br />
Advantages of the <strong>de</strong>gassing technologies:<br />
removes alkalis and inclusions when chlorine<br />
is used; allows treatment with 2 to 8 rotor systems<br />
for metal flow rates from 20 up to 1,500<br />
kg/min for the ACD; avoids loss of metal due<br />
to alloy changes for the ACD; avoids need to<br />
heat unit for the ACD; suits inline salt injection<br />
system.<br />
Technology comparison – conventional vs<br />
sealed ACD: In the recent years, the ACD has<br />
been improved to operate un<strong>de</strong>r sealed conditions<br />
(see Fig. 5 for <strong>de</strong>sign changes).<br />
Conventional unit: Conventional ACDs<br />
create forced air circulation through the interior<br />
of the hood. This mo<strong>de</strong> of operation<br />
originally served to eliminate dross reactivity<br />
by (burning) after treatment of AlMg alloys.<br />
Sealed unit: The basic principle is to maintain<br />
the insi<strong>de</strong> of the ACD hood un<strong>de</strong>r argon<br />
atmosphere to exclu<strong>de</strong> oxygen as far as possible.<br />
For that purpose, the ACD hood has been<br />
completely re<strong>de</strong>signed. All means have been<br />
implemented to eliminate air infiltration.<br />
Benefits of sealed ACD: lowers dross generation;<br />
allows ACD operation without the<br />
use of chlorine; reduces emission of particulate<br />
matter.<br />
In-line salt feeding system: In-line salt injection<br />
involves adding of very small amounts<br />
of solid flux un<strong>de</strong>rneath the molten aluminium<br />
surface. This technology takes advantage<br />
of the strong shearing forces <strong>de</strong>veloped<br />
around the ACD rotor heads to properly disperse<br />
the liquid salt droplets. The solid flux<br />
assists alkali removal and inclusion removal<br />
using commercial fused or non-fused MgCl 2 /<br />
KCl mixtures.<br />
This approach is an alternative for plants<br />
that want to avoid or eliminate gaseous chlorine<br />
injection in in-line <strong>de</strong>gassers. The theory<br />
of alkali and inclusion removal from aluminium<br />
by using MgCl 2 /KCl mixtures is well <strong>de</strong>scribed<br />
in the literature.<br />
Brief <strong>de</strong>scription of the equipment: The inline<br />
flux fee<strong>de</strong>r takes advantage of the ACD<br />
rotor <strong>de</strong>sign to inject solid flux through the<br />
shaft central opening. The flux is then directly<br />
<strong>de</strong>livered insi<strong>de</strong> the rotating disperser un<strong>de</strong>rneath<br />
the metal surface. Hence, the liquefied<br />
salt droplets are efficiently dispersed within<br />
the molten metal. This configuration, as for<br />
salt injection, is the key element for the �<br />
59 ALUMINIUM · 1-2/2008<br />
59
ALUMINIUM SMELTING INDUSTRY<br />
efficiency of the ACD salt injection<br />
process. Thanks to its patented disperser<br />
<strong>de</strong>sign, the ACD is among the<br />
few technologies that can offer inline<br />
salt injection.<br />
A more <strong>de</strong>tailed <strong>de</strong>scription can be<br />
found in the TMS article presented in<br />
2007.<br />
Metallurgical performances with<br />
different configurations of ACDs<br />
To compare different configurations<br />
in various plants, metallurgical performance<br />
tests have been performed,<br />
the results of which are briefly presented<br />
below. The ACD configurations<br />
are:<br />
• ACD without chlorine<br />
• ACD with chlorine (original<br />
<strong>de</strong>sign, where chlorine is injected<br />
through all but one rotor)<br />
• ACD with chlorine (by limiting<br />
the number of rotors for chlorine<br />
injection)<br />
• ACD with salt injection (in replacement<br />
of chlorine).<br />
Hydrogen removal: The most important<br />
function of an ACD is to remove<br />
dissolved hydrogen from molten aluminium.<br />
It is worth mentioning that<br />
using the ACD for hydrogen removal<br />
is equivalent to using a box type <strong>de</strong>gasser.<br />
Since the hydrogen escapes<br />
in bubbles of other gases, there is no<br />
difference between using the ACD argon<br />
with chlorine, without chlorine or<br />
even with the salt injection system. In<br />
fact, the results <strong>de</strong>pend on the volume<br />
Fig. 6: Salt injection system<br />
of gas injected, the efficiency of gas<br />
dispersion, and the resi<strong>de</strong>nce time of<br />
the gas bubbles in the molten metal.<br />
Using the AlSCAN method to<br />
monitor the results, ACDs have shown<br />
similar <strong>de</strong>gassing efficiency with or<br />
without chlorine. Results based on the<br />
latest improvement using an MgCl 2<br />
based salt to replace chlorine have<br />
shown equivalent removal performances<br />
in similar process conditions.<br />
Inclusion removal:<br />
Without use of chlorine: Over the<br />
last years, there has been a worldwi<strong>de</strong><br />
movement toward the elimination of<br />
chlorine from cast houses because of<br />
environmental, hygiene and safety<br />
concerns.<br />
Six years ago, only a few ACDs<br />
were operated without chlorine injection.<br />
Inclusion removal was characterised<br />
as inconsistent, to say the<br />
least. The dross generated insi<strong>de</strong> the<br />
ACD was found to be much ‘wetter’<br />
without chlorine than with it. In these<br />
conditions, the inclusions can be easily<br />
re-entrained into the melt, thus<br />
explaining the low or non existent<br />
inclusion removal.<br />
Nowadays, more than 20 ACDs of<br />
the latest sealed <strong>de</strong>sign are in operation<br />
using argon only.<br />
However, even with sealed ACDs,<br />
which generate and show no surface<br />
dross, inclusion removal efficiency is<br />
still inconsistent without chlorine. To<br />
achieve consistent inclusion removal,<br />
a modified agent is nee<strong>de</strong>d to make<br />
the inclusions less wettable, so that<br />
they stay separate<br />
at the aluminium<br />
surface.<br />
With use of<br />
chlorine: It is well<br />
documented that<br />
consistent inclusion<br />
removal efficiency<br />
through in-line <strong>de</strong>gassing<br />
requires a<br />
minimum input of<br />
chlorine.<br />
From the first<br />
<strong>de</strong>velopment of the<br />
ACD in the early<br />
1990s, chlorine was<br />
injected un<strong>de</strong>rneath<br />
the metal surface<br />
through all the rotors<br />
but the last one,<br />
which injects argon only. The typical<br />
inclusion removal performance associated<br />
with a standard chlorine injection<br />
configuration may vary from 25<br />
up to 60 percent. However, it is important<br />
to highlight that the higher the<br />
cleanliness of the metal coming from<br />
the furnace, the lower the proportion<br />
of inclusion removal will be.<br />
Recent plant experiments have<br />
shown that limiting the number of<br />
rotors that inject chlorine can help<br />
achieve higher and more consistent<br />
inclusion removal efficiencies<br />
(Fig. 7).<br />
Salt Injection: As published at the<br />
last TMS, inclusion removal is more<br />
efficient when salt is used instead of<br />
chlorine (Fig. 8).<br />
Alkali removal: Except for the configuration<br />
that uses argon only, alkali<br />
removal is equivalent for all other<br />
configurations (with chlorine or salt<br />
injection), with a removal efficiency<br />
of 40 to 60 percent.<br />
As a comparison, the performance<br />
obtained without injection of a chemically<br />
active reactant (argon only) are<br />
also inclu<strong>de</strong>d in the figure. Argon<br />
alone achieved a 20 percent efficiency<br />
of alkali removal since the turbulent<br />
mixing vaporizes sodium into the<br />
bubbles. In<strong>de</strong>ed, sodium’s high activity<br />
coefficient and vapour pressure<br />
favour it removal in the ACD.<br />
Conclusion<br />
To the authors’ knowledge, of a dozen<br />
customers who have installed or <strong>de</strong>monstrated<br />
a strong interest in the TAC<br />
over the six last years, most have coupled<br />
their machines with a skimming<br />
machine. The new automatic skimming<br />
machines remove bath more<br />
precisely than the manual method,<br />
and they avoid health and safety problems<br />
for the operators.<br />
It is worth noting that the use of<br />
the flux injection technology is more<br />
and more an option for smelters and<br />
recycling plants to treat liquid metal<br />
in furnaces. A lower magnesium chlori<strong>de</strong><br />
content in salt flux has proved as<br />
effective as a higher content.<br />
With the ACD, reducing the number<br />
of rotors injecting chlorine has given<br />
similar or even better results in terms<br />
of alkali or inclusion removal.<br />
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Finally, as presented at the TMS 2007,<br />
the new salt injection system offers an<br />
improved solution which completely<br />
eliminates chlorine gas from the cast<br />
house.<br />
Acknowledgement<br />
Sincere thanks are due to the Alcan’s<br />
personnel and the STAS <strong>de</strong>sign team,<br />
without whose <strong>de</strong>dication the success<br />
of this work would not have been possible.<br />
Authors<br />
Bruno Maltais, Dominique Privé and<br />
Marc-André Thibault are with STAS Inc.,<br />
based in Chicoutimi, Canada. Fig. 7: Inclusion removal efficiency<br />
Fig. 8: Inclusion removal efficiency: in-line salt injection<br />
versus chlorine injection<br />
Fig. 9: Alkali removal efficiency: argon only, chlorine injection,<br />
salt injection<br />
Auto control system for quality casting<br />
J. Strömbeck, Hono<br />
This article explains how an existing<br />
casthouse can easily become<br />
a mo<strong>de</strong>rn automated factory using<br />
Precimeter’s step-by-step process<br />
upgra<strong>de</strong> philosophy. The foundry<br />
industry has traditionally been<br />
regar<strong>de</strong>d as a low tech, heavy and<br />
dangerous working environment.<br />
With the Precimeter ‘auto control<br />
system’ all this can change into a<br />
mo<strong>de</strong>rn, clean and safe environment.<br />
Traditionally in casting, the metal<br />
flow has been manually controlled by<br />
an operator. Casting plants <strong>de</strong>pend on<br />
their most experienced operators for<br />
high productivity and good quality.<br />
These professionals are getting har<strong>de</strong>r<br />
to find. If they are on sick leave, or replaced<br />
by someone less experienced,<br />
production suffers.<br />
Often, the control of metal flow into<br />
the mould <strong>de</strong>pends on floaters. These<br />
<strong>de</strong>vices are inaccurate since they can<br />
change over time as frozen metal adheres<br />
to them or they can malfunction<br />
due to mechanical friction and wear.<br />
The throttling <strong>de</strong>vice moves in direct<br />
proportion to the floater position,<br />
and disregards the characteristics of<br />
flow rate versus sli<strong>de</strong>r position. The<br />
level controlled is <strong>de</strong>termined by the<br />
individual floater, and so cannot be<br />
changed during the cast. Also, floaters<br />
provi<strong>de</strong> no inherent way of recording<br />
the metal levels using floaters.<br />
The Precimeter auto control sys-<br />
tem revolutionizes the whole casting<br />
process by offering step-by-step<br />
automation from a single metal level<br />
control to a fully automatic casting<br />
process. The system provi<strong>de</strong>s benefits<br />
including:<br />
• Improved quality due to steady<br />
metal levels throughout the process<br />
• Increased productivity since<br />
eliminating human error gives<br />
better recovery rates<br />
• Safer working environment for<br />
the operators<br />
• Casting repeatability<br />
• Documentation of the process<br />
• Step-by-step improvements<br />
• Flexibility in setting metal levels<br />
throughout the casting process<br />
• Better use of manpower. �<br />
61 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
Fig. 1: Stationary furnace controlled by<br />
TXP-6E tap-out actuator, ProH sensor and<br />
control system<br />
Fig. 2: Tilting furnace controlled by ProH<br />
sensor and control system<br />
Fig. 3: Control of molten metal level for<br />
rod casting with PXP-2E pin position<br />
actuator<br />
Fig. 4: Control of molten metal level in<br />
sheet casting with PXP-2E actuator<br />
Illustrations: Precimeter<br />
The concept of a fully automatic casting<br />
process can be implemented in existing<br />
casting processes. Using a step<br />
by step approach one can upgra<strong>de</strong><br />
one part at a time.<br />
The normal approach to automating<br />
casting begins by analysing the<br />
current manual process and isolating<br />
the crucial elements to optimize<br />
the return on the initial investment.<br />
This could for example begin with<br />
automating the furnace control or the<br />
filling of the mould.<br />
The way to begin <strong>de</strong>pends on what<br />
the customer regards as the key element<br />
to improve. Once installed, the<br />
auto control system is ready for the next<br />
level of automation just by adding the<br />
Precimeter components, which consist<br />
of the well known, market leading molten<br />
metal level sensor ProH together<br />
with a range of suitable actuators.<br />
Today, most furnace tapping processes<br />
are manually controlled. There<br />
are two main types of furnaces: tilting<br />
and stationary.<br />
The tilting furnace employs a hydraulic<br />
piston that slowly tilts the<br />
furnace to let the molten metal flow<br />
into the laun<strong>de</strong>r system. The tilting action<br />
is manually controlled using push<br />
buttons up / down. The operator looks<br />
at the level downstream and uses his<br />
experience to control the metal level<br />
in or<strong>de</strong>r to get a good flow of molten<br />
metal.<br />
The stationary (also called gravity)<br />
furnace has a low positioned tap<br />
hole which is opened to start casting.<br />
The operator adjusts the flow manually<br />
using a control rod to a cone in<br />
the tap hole. This is a dangerous operation<br />
where the operator is close<br />
to the molten metal; in addition, it is<br />
very difficult to estimate by eye and<br />
accurately control the level further<br />
downstream. The process obviously<br />
<strong>de</strong>pends on an expert proficient with<br />
the process.<br />
Precimeter has, together with<br />
leading furnace manufacturers and<br />
aluminium foundries, studied and<br />
<strong>de</strong>veloped advanced, affordable solutions<br />
to automate these operations.<br />
The first priority for the stationary<br />
furnace has of course been the safety<br />
of the operator. The employer is responsible,<br />
and cannot ignore the risk<br />
to a man standing close to the furnace<br />
tap out hole for hours to adjust the<br />
control rod. Such working hazards<br />
must be avoi<strong>de</strong>d.<br />
New as well as old stationary furnaces<br />
can now be equipped with a tapout<br />
actuator TXP-6E or TXP-10. The<br />
actuator clamps onto the control rod<br />
with the cone, moving it in or out of the<br />
tap hole, so as to maintain the <strong>de</strong>sired<br />
metal level in the laun<strong>de</strong>r. The actual<br />
metal level downstream is measured<br />
with the ProH digital camera sensor,<br />
which feeds a signal back to a closed<br />
loop auto control system, type MLC<br />
M1, controlling the tap-out actuator.<br />
This complete system (actuator,<br />
sensor and control unit) guarantees<br />
the <strong>de</strong>sired metal level on set point<br />
within an accuracy of 0.5 mm. This is<br />
better than any human operator can<br />
achieve, and improves safety for the<br />
operators, who do not need to stand as<br />
close to the molten metal (Fig. 1).<br />
Accurate level control ensures<br />
quality casting by reducing variables<br />
to constants. A computerized control<br />
system is able to reliably repeat the<br />
same casting results over and over<br />
again. This means less scrap and less<br />
down time.<br />
A tilting furnace does not represent<br />
the same hazards for the employees as<br />
a stationary furnace. The control buttons<br />
can be placed further away from<br />
the molten metal, so the operator can<br />
be further from the danger zone. But<br />
the operator still has a great difficulty<br />
in keeping the same metal level during<br />
each cast and from cast to cast.<br />
This regulation <strong>de</strong>pends on an experienced<br />
operator who estimates metal<br />
level by eye and tries to keep it constant<br />
only by manual adjustment. The<br />
solution to this problem is the new<br />
Precimeter system for tilting furnaces<br />
that uses a ProH sensor measuring the<br />
level downstream. When the operator<br />
<strong>de</strong>ci<strong>de</strong>s that the level is perfect, he<br />
switches to automatic mo<strong>de</strong>, and then<br />
the tilting of the furnace is controlled<br />
automatically; keeping the level on set<br />
point within 0.5 mm (Fig. 2).<br />
This system employs a ProH camera<br />
sensor and an auto control system<br />
MLC M1 as a very convenient retrofit<br />
kit. This leads to less scrap, less down<br />
time and better use of manpower as it<br />
frees up one operator from the duties<br />
of watching the metal levels.<br />
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Moving one step further down in the process, there is<br />
obviously a need to control the metal levels in the mould.<br />
This is easily done with a flow control actuator and a<br />
ProH level sensor reading the metal level in the mould.<br />
The company has experience with casting installations,<br />
starting with controlling the mould and implementing<br />
the auto control system MLC M1 or A1, <strong>de</strong>pending on<br />
how far the plant wants to automate. See figures 3 (rod),<br />
4 (sheet) and 5 (ingot) as examples of different types of<br />
systems installed in production plants.<br />
The next natural step is to combine the furnace automation<br />
with the mould automation. This combined system<br />
is called ‘auto control flexible’, and it can handle up<br />
to 4 different levels in a casting process. It works with<br />
pre-programmed casting parameters and has an excellent<br />
repeatability. The system is easily handled through<br />
Fig. 5: Control of<br />
molten metal level<br />
in ingot casting<br />
with TXP-6E and<br />
starter dam actuators<br />
Fig. 6: Billet casting with<br />
ProH sensor and Precimeter<br />
control system<br />
Fig. 7: Slab casting<br />
with PXP-2E and<br />
starter dam actuators<br />
the operator interface, a touch screen. See figure 6 (billet<br />
casting) as an example.<br />
For a more advanced casting process control, the company<br />
offers the auto control system ‘MLC Advanced’. This<br />
system fully automates management of the entire casting<br />
process. Using this system has proved that it increases productivity<br />
and produces less rejects. The process can be<br />
recor<strong>de</strong>d for traceability, and it learns to repeat the same<br />
top quality casting time after time. See figure 7 (slab) as<br />
an example.<br />
The company’s auto control systems can communicate<br />
with all major PLC brands used in factory automation<br />
worldwi<strong>de</strong>; they can interconnect with any existing factory<br />
process control system to make the upgra<strong>de</strong> smooth.<br />
To provi<strong>de</strong> safe and accurate function, all of the<br />
above systems use the ‘Smart Filter’ software <strong>de</strong>veloped<br />
and perfected by Precimeter’ software engineers during<br />
years of testing. The systems are being sold and installed<br />
worldwi<strong>de</strong> by members of the company group and their<br />
representatives. These inventions take the industry a<br />
step forward by eliminating hazards, reducing scrap and<br />
rejects, improving quality, and utilizing manpower in a<br />
more efficient way.<br />
Author<br />
Jan Strömbeck, M. Sc., is Managing Director of Precimeter Control<br />
AB, based in Hono near Gothenburg in Swe<strong>de</strong>n.<br />
63 ALUMINIUM · 1-2/2008<br />
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ALUMINIUM SMELTING INDUSTRY<br />
History of intensive mixing<br />
for ano<strong>de</strong> paste used in aluminium electrolysis<br />
B. Hohl, Hardheim<br />
About 84% of the world’s production<br />
of primary aluminium uses<br />
prebaked ano<strong>de</strong>s: this amounted<br />
to approximately 30 million tonnes<br />
of the 35.5 million tonnes ma<strong>de</strong> in<br />
2006. The remaining 5.5m tonnes<br />
came from ol<strong>de</strong>r works with Soe<strong>de</strong>rberg<br />
technology so that the<br />
requirement for ano<strong>de</strong> paste was<br />
about 16.5m tonnes for prebaked<br />
ano<strong>de</strong>s and 3m tonnes for Soe<strong>de</strong>rberg.<br />
More than every second<br />
prebaked ano<strong>de</strong> is produced from<br />
either completely (Eirich Mixing<br />
Casca<strong>de</strong>, ‘EMC’) or partially (cooler)<br />
intensively prepared paste. So,<br />
intensive mixers for ano<strong>de</strong> paste<br />
have become state-of-the-art in the<br />
primary aluminium industry.<br />
Remixing and cooling<br />
of ano<strong>de</strong> paste<br />
Already in the 1970s, individual intensive<br />
mixers were used as continuously<br />
operating coolers for ano<strong>de</strong> paste e. g.,<br />
in the Netherlands a n d<br />
in Bahrain, then<br />
an exten-<br />
Fig. 1:<br />
Intensive<br />
mixing principle<br />
tinuously operating Eirich<br />
intensive mixer proved it<br />
could not only cope reliably<br />
with cooling but could<br />
also achieve excellent homogenization<br />
of the paste.<br />
By directly adding water<br />
which immediately evaporates<br />
from the ano<strong>de</strong> paste<br />
it achieves far higher cooling<br />
capacities than established<br />
systems have ever<br />
reached.<br />
On top of that is the<br />
effect of an almost ‘costfree’<br />
homogenizer: the<br />
cooler also achieves a consi<strong>de</strong>rably<br />
improved paste quality compared to<br />
single-step preparation thanks to the<br />
relatively long retention time of 4 to<br />
5 minutes, the intensive mixing effect,<br />
and the additionally introduced mixing<br />
energy of approximately 4 kWh/t.<br />
This is why hardly any single-step<br />
paste preparation lines were built in<br />
the last 15 years. In the same period,<br />
numerous existing plants were retrofitted<br />
with Eirich intensive remixercoolers.<br />
Integrating this additional<br />
machine into an existing building<br />
often posed a great challenge for the<br />
engineers. In the end, they always<br />
found a solution so as to profit from<br />
the <strong>de</strong>cisive advantages.<br />
The advantages are:<br />
• Agglomerate-free paste with<br />
constant temperature<br />
• Essentially more stable paste<br />
quality by reducing parameter<br />
variations to less than 50%<br />
Fig. 3: Development of baked <strong>de</strong>nsity<br />
sive test series at the Pechiney works in<br />
Sabart (France) led to the breakthrough<br />
of this technology around 1990 with<br />
two more machines in France and<br />
Australia. At that time, the customer<br />
was looking for a paste cooler of high<br />
performance and efficiency. The con- Fig. 2: Green paste porosity as an indicator of mixing efficiency<br />
• Hot mixing temperature<br />
optimized (increased) since it<br />
becomes in<strong>de</strong>pen<strong>de</strong>nt of the<br />
forming temperature<br />
• Long retention time and intensive<br />
remixing of the paste<br />
• Additional mixing energy<br />
• Higher green and baked <strong>de</strong>nsity<br />
and/or less pitch consumption<br />
• Lower electric resistance of the<br />
ano<strong>de</strong><br />
• Clearly reduced porosity and<br />
optimized pore structure<br />
• Lower chemical reactivity<br />
• Allows some overall increase in<br />
the performance of the paste<br />
preparation.<br />
It is important to note that such plants<br />
have a greater construction height because<br />
they need an efficient exhaust<br />
air treatment system to extract steam<br />
and pitch fumes efficiently.<br />
The effect of the Eirich cooler becomes<br />
e<strong>special</strong>ly apparent when retrofitting<br />
into existing lines because here<br />
64 ALUMINIUM · 1-2/2008<br />
Illustrations: Eirich
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY TMS & ALUMINIUM INDIA 2008<br />
Fig. 4: Flow diagram EMC<br />
a direct comparison of preparation<br />
quality is easily to do.<br />
All-intensive preparation<br />
of ano<strong>de</strong> paste<br />
The success of the intensive mixing<br />
principle for paste cooling led to the<br />
<strong>de</strong>velopment of the EMC. Two seriesconnected<br />
intensive mixers perform<br />
first hot mix the coke and binding<br />
pitch and then subsequent remix and<br />
cool the paste. The operational advantages<br />
of the Eirich intensive mixer<br />
show up as low operating and maintenance<br />
costs, short standstill periods<br />
for any wear-related repairs, long re-<br />
Fig. 5: RV24 EMC 35 t/h at Aostar China<br />
tention time, compensation<br />
of short-time variations in<br />
paste composition, e<strong>special</strong>ly<br />
efficient and thus mo<strong>de</strong>rate<br />
energy input etc. On top<br />
of that the machines are also<br />
available for up to the highest<br />
throughput rates so that<br />
an ano<strong>de</strong> plant with just one<br />
single preparation line can<br />
supply most mo<strong>de</strong>rn smelters<br />
with more than 600,000<br />
tpy of aluminium. EMC lines<br />
are available for throughputs<br />
from 10 t/h to more than 60<br />
t/h. In recent years several<br />
lines were built in Europe,<br />
Africa and East Asia. In 2008,<br />
the first high-performance<br />
line with a throughput rate<br />
of 60 t/h will be supplied to<br />
an aluminium smelter at the<br />
Persian Gulf.<br />
Conclusion<br />
Thanks to its <strong>de</strong>cisive benefits, Eirich<br />
intensive mixing has already become<br />
proven technology in the ano<strong>de</strong> paste<br />
preparation sector. Further technical<br />
and commercial growth is sure to follow.<br />
The future lies with continuous ano<strong>de</strong><br />
paste preparation thanks to their<br />
high efficiency at low investment and<br />
operating costs.<br />
References<br />
1) P. Stokka, Green paste porosity as an<br />
indicator of mixing efficiency, Light Metals<br />
TMS 1997, pp. 565-568.<br />
2) B. Hohl and L. Gocnik, Installation of<br />
an ano<strong>de</strong> paste cooling system at Slovalco,<br />
Light Metals TMS 2002, pp. 583-586.<br />
3) B. Hohl and You Lai Wang,<br />
Experience Report – Aostar<br />
– ano<strong>de</strong> paste preparation<br />
by means of a continuously<br />
operated intensive mixing<br />
casca<strong>de</strong>, Light Metals TMS<br />
2006, pp. 583-587.<br />
Author<br />
Dipl.-Ing. Berthold Hohl is<br />
Product Manager Carbon<br />
Technology at Maschinenfabrik<br />
Gustav Eirich GmbH<br />
& Co KG, Hardheim, Germany.<br />
65 ALUMINIUM · 1-2/2008<br />
ALUMINIUM · 1-2/2008 65
Fotos: Ebner<br />
MARKT UND TECHNIK<br />
Ebner Industrieofenbau<br />
Anspruchsvolle Anwendungen<br />
bei <strong>de</strong>r Wärmebehandlung<br />
B. Rieth, Meerbusch<br />
Luftaufnahme vom Ebner-Standort Leonding nahe Linz, Österreich<br />
Aerial view of Ebner site at Leonding near Linz, Austria<br />
Diversifizierung ist eine <strong>de</strong>r Strategien,<br />
mit <strong>de</strong>nen internationale Anlagenbaufirmen<br />
versuchen, durch<br />
eine Erweiterung ihres Portfolios<br />
Einbußen an Sachlieferungen auszugleichen,<br />
die sie durch frühere<br />
Zugeständnisse zu umfangreichen<br />
Lokalfertigungen in aufstreben<strong>de</strong>n<br />
Märkten wie China hinnehmen<br />
mussten. Dies gilt nicht für die<br />
österreichische Firma Ebner Industrieofenbau,<br />
die zu <strong>de</strong>n weltweit<br />
renommierten Anbietern von<br />
Wärmebehandlungsanlagen zählt.<br />
Die Erfolgsfaktoren dieses Unternehmens<br />
sind Spezialisierung<br />
auf Hochtechnologie, Qualität aus<br />
eigenen Fertigungsbetrieben und<br />
stetige Produktentwicklung.<br />
Schmelz- und Gießöfen sowie konventionelle<br />
Erwärmungsanlagen im<br />
Strangpressbereich sucht man bei<br />
Ebner vergeblich. Statt<strong>de</strong>ssen hat sich<br />
das Familienunternehmen im Laufe<br />
seiner 60-jährigen Geschichte auf an<strong>de</strong>re<br />
Produktlinien für die Wärmebehandlung<br />
von Halbzeugen aus Stahl<br />
und NE-Metallen konzentriert und<br />
mit diesen eine führen<strong>de</strong> Marktposition<br />
erreicht. Dieses sind:<br />
• Haubenöfen für Stahlbandbun<strong>de</strong><br />
sowie Stahldrahtbun<strong>de</strong><br />
• Stahlbandvergüteanlagen<br />
• Bandglühofenanlagen für legierte<br />
und unlegierte Stahlbän<strong>de</strong>r<br />
• Haubenöfen für Messingband-<br />
bun<strong>de</strong> sowie Messingdrahtbun<strong>de</strong><br />
• Stoßöfen zum Homogenisieren<br />
und Anwärmen von <strong>Alu</strong>minium-<br />
Walzbarren<br />
• Durchlaufglühöfen als Bandsch<strong>web</strong>eöfen<br />
zum kontinuierlichen<br />
Glühen von Bän<strong>de</strong>rn sowie<br />
Rollenherdöfen für <strong>Alu</strong>miniumplatten<br />
und -bleche<br />
• Kammer-Glühöfen für <strong>Alu</strong>miniumbun<strong>de</strong><br />
in Einzel- o<strong>de</strong>r Mehrfachbelegung.<br />
Der hohe technologische Anspruch<br />
<strong>de</strong>r Wärmebehandlungsanlagen von<br />
Ebner drückt sich im gemeinsamen<br />
„Hicon“-Logo aus. Es steht für High<br />
Convection und be<strong>de</strong>utet <strong>de</strong>n Einsatz<br />
<strong>de</strong>r von Ebner entwickelten Hochkonvektions-Technologie,<br />
die sich<br />
durch eine funktionsspezifische und<br />
verlustarme Umwälzung <strong>de</strong>r Ofenatmosphäre,<br />
optimierten Medienfluss<br />
um die gesamte Charge sowie einen<br />
sehr geringen Energieverbrauch dank<br />
effizienter Isolierung und externer<br />
Rekuperatoren für je<strong>de</strong> Ofenzone<br />
auszeichnet.<br />
Ebner Industrieofenbau<br />
Demanding<br />
heat treatment<br />
applications<br />
B. Rieth, Meerbusch<br />
Diversification is one of the strategies<br />
with which international<br />
plant manufacturers seek, by<br />
extending their product range, to<br />
counteract the inroads ma<strong>de</strong> into<br />
<strong>special</strong>ist supply sectors affected<br />
by earlier concessions which encouraged<br />
local manufacture in <strong>de</strong>veloping<br />
markets such as China.<br />
This does not apply to the Austrian<br />
company Ebner Industrieofenbau,<br />
one of the most renowned<br />
suppliers of heat treatment equipment<br />
worldwi<strong>de</strong>. The factors that<br />
shape the company’s success are<br />
<strong>special</strong>isation in high technology,<br />
quality from its own production<br />
operations, and continual product<br />
<strong>de</strong>velopment.<br />
Do not expect to get melting and<br />
casting furnaces and conventional<br />
heating units for the extrusion sector<br />
from Ebner. Over its 60-year history<br />
the family-owned firm has concentrated<br />
on other product lines for the<br />
heat treatment of steel and NF-metal<br />
semis, and has achieved a marketleading<br />
position with them. They inclu<strong>de</strong>:<br />
• bell annealing furnaces for steel<br />
strip and wire coils<br />
• steel strip tempering units<br />
• strip annealing units for alloyed<br />
and unalloyed steel strips<br />
• bell annealing furnaces for brass<br />
strip and wire coils<br />
• pusher-type furnaces for homo-<br />
genising and heating aluminium<br />
rolling ingots<br />
• continuous furnaces as floatertype<br />
units for the continuous<br />
annealing of strips, and roller<br />
hearth furnaces for aluminium<br />
plates and sheets<br />
• chamber furnaces for annealing<br />
aluminium coils individually or<br />
in batches.<br />
The high technological sophistication<br />
of Ebner heat treatment units is<br />
proclaimed by the tra<strong>de</strong>mark ‘Hicon’,<br />
66 ALUMINIUM · 1-2/2008
This stands for ‘High Convection’,<br />
<strong>de</strong>noting the use of the high-convection<br />
technology <strong>de</strong>veloped by Ebner<br />
which is characterised by functionspecific<br />
and low-loss circulation of<br />
the furnace atmosphere, optimised<br />
media flow around the whole charge,<br />
and very low energy consumption<br />
thanks to the effective insulation and<br />
external recuperators for each furnace<br />
zone.<br />
Orientation towards<br />
the aluminium industry<br />
Besi<strong>de</strong>s the Hicon/H 2 annealing technique,<br />
which is preferably used for<br />
annealing steel strip coils in a pure<br />
hydrogen atmosphere un<strong>de</strong>r high<br />
convection conditions, Ebner has <strong>de</strong>veloped<br />
numerous technologies and<br />
<strong>de</strong>signs for heat treatment units for<br />
the aluminium industry. Examples<br />
are:<br />
• an optimised slot nozzle system<br />
for pusher-type furnaces, which<br />
ensures rapid and uniform<br />
heating of the whole charge in<br />
the furnace<br />
• an air-flow-controlled carrier<br />
system, which supports an<br />
aluminium strip up to 8 mm thick<br />
in the floater-type strip furnace<br />
• optimised quenching technology<br />
for the quenching of plates, bars<br />
and sections in water after the<br />
roller hearth furnace.<br />
The key components important for a<br />
heat treatment unit, such as fan aggregates<br />
for circulating the furnace<br />
atmosphere, burners, radiation tubes<br />
and much more, were <strong>de</strong>veloped in<br />
the company’s own laboratory, are<br />
constantly being improved, and tested<br />
for operational reliability in long-term<br />
tests. They are of course produced in<br />
the company’s own workshops.<br />
With its own <strong>de</strong>sign <strong>de</strong>partment<br />
for the sectors of mechanical engineering,<br />
gas and regulation technology,<br />
electro-technology, automation<br />
and visualisation, Ebner can not only<br />
react more flexibly to customers’<br />
wishes and ever-stricter customer<br />
standards, but also take advantage of<br />
every improvement and accumulated<br />
knowledge from the commissioning<br />
of furnace units for the <strong>de</strong>sign of new<br />
equipment. �<br />
ALUMINIUM · 1-2/2008<br />
Ausrichtung auf<br />
die <strong>Alu</strong>miniumindustrie<br />
Neben <strong>de</strong>r Hicon/H 2 -Glühtechnik, die<br />
vorzugsweise zum Glühen von Stahlbandbun<strong>de</strong>n<br />
in reiner Wasserstoffatmosphäre<br />
unter Hochkonvektionsbedingungen<br />
eingesetzt wird, hat Ebner<br />
eine Vielzahl von Technologien und<br />
Konstruktionen für Wärmebehandlungsanlagen<br />
für die <strong>Alu</strong>miniumbranche<br />
entwickelt. Beispiele sind:<br />
• ein optimiertes Schlitzdüsen-<br />
system für Stoßöfen, das eine<br />
rasche und gleichmäßige<br />
Erwärmung <strong>de</strong>r gesamten<br />
Charge im Ofen garantiert,<br />
• ein luftströmungsgesteuertes<br />
Tragesystem, das ein bis zu<br />
8 mm dickes <strong>Alu</strong>miniumband<br />
im Sch<strong>web</strong>ebandofen trägt<br />
• eine optimierte Quenchtechnologie<br />
zum Abschrecken von<br />
Platten, Stangen und Profilen im<br />
Wasser beim Rollenherdofen.<br />
Die für eine Wärmebehandlungsanlage<br />
wichtigen Schlüsselkomponenten<br />
wie Ventilatoraggregate zum Umwälzen<br />
<strong>de</strong>r Ofenatmosphäre, Brenner,<br />
Strahlrohre und vieles mehr wur<strong>de</strong>n<br />
im hauseigenen Labor entwickelt,<br />
permanent verbessert und in Langzeittests<br />
über Jahre auf ihre Betriebsicherheit<br />
geprüft. Gefertigt wer<strong>de</strong>n<br />
sie selbstverständlich in <strong>de</strong>n eigenen<br />
Werken.<br />
Mit eigenen Konstruktionsabteilungen<br />
in <strong>de</strong>n Bereichen Maschinenbau,<br />
Gas- und Regeltechnik,<br />
Elektrotechnik, Automatisierung und<br />
Visualisierung kann Ebner nicht nur<br />
MARKETS AND TECHNOLOGY<br />
Industrieofenbau seit 1902<br />
��������������������������������������<br />
auf Kun<strong>de</strong>nwünsche und die immer<br />
strenger wer<strong>de</strong>n<strong>de</strong>n Kun<strong>de</strong>nstandards<br />
flexibel reagieren, son<strong>de</strong>rn<br />
bei Neukonstruktionen von Wärmebehandlungsanlagen<br />
auch rasch<br />
sämtliche Weiterentwicklungen und<br />
Erkenntnisse berücksichtigen, die bei<br />
<strong>de</strong>n Inbetriebnahmen von Ofenanlagen<br />
gemacht wur<strong>de</strong>n.<br />
Marktführer bei Stoßöfen<br />
Beispiel Stoßöfen für Walzbarren: Mit<br />
bisher 35 weltweit gebauten Anlagen<br />
in <strong>de</strong>n letzten 20 Jahren gilt Ebner<br />
als Marktführer auf diesem Gebiet.<br />
Stoßöfen wer<strong>de</strong>n eingesetzt zum<br />
Homogenisieren und Anwärmen auf<br />
Walztemperatur von Walzbarren mit<br />
Gewichten bis zu 30 Tonnen und Abmessungen<br />
bis zu 8650 x 2200 x 650<br />
mm. Kürzest mögliche Anwärmzeiten<br />
mit einer maximalen Temperaturdifferenz<br />
von 6o K über die gesamte<br />
Charge wer<strong>de</strong>n durch Anwendung<br />
<strong>de</strong>r Hicon-Technologie erreicht.<br />
Neben zwei Stoßöfen, die im neuen<br />
Warmwalzwerk von Yantai Nanshan<br />
in China bereits in Betrieb genommen<br />
wur<strong>de</strong>n, liefert Ebner nach China drei<br />
weitere für Asia <strong>Alu</strong>minium sowie<br />
zwei für das neue Qualitäts-Bandwalzwerk<br />
von Xiamen Xiashun. Auch<br />
in Russland kommen neue Stoßöfen<br />
von Ebner zum Einsatz, und zwar im<br />
Alcoa-Werk Samara.<br />
Große Erwartungen auf eine Belebung<br />
<strong>de</strong>s nordamerikanischen Marktes<br />
knüpft Ebner an einen neuen<br />
Auftrag von Alcoa Rigid Packaging<br />
in Knoxville, Tennessee. Die �<br />
������������� ���������������� ������������<br />
�������������� �������������� ��������������<br />
����������� � ����<br />
�����������������������������������������<br />
����������������������������������������������<br />
���������������������������������������������������������������������<br />
<strong>Alu</strong>minium 2008 in Essen, 23.–25. September, Halle 4, Stand 4C24<br />
67
MARKT UND TECHNIK<br />
bei<strong>de</strong>n Stoßöfen, die im Herbst 2008<br />
in Betrieb gehen wer<strong>de</strong>n, können mit<br />
48 Barren, das entspricht 1.200 Tonnen,<br />
beschickt wer<strong>de</strong>n. Sie sind damit<br />
die weltgrößten dieser Bauart. Nicht<br />
nur durch die verbesserte Qualität<br />
und die niedrigeren Wartungskosten,<br />
son<strong>de</strong>rn vor allem auch durch die<br />
von Ebner garantierte hohe Energieausnutzung<br />
angesichts <strong>de</strong>r enorm gestiegenen<br />
Energiepreise rechnet sich<br />
diese Investition für Alcoa innerhalb<br />
weniger Jahre.<br />
Vergüten von <strong>Alu</strong>minium-Platten<br />
und Blechen: Wärmebehandlung<br />
im Grenzbereich<br />
Der von <strong>de</strong>r Luftfahrtindustrie ausgehen<strong>de</strong><br />
Investitionsboom für Plattenerzeugungsanlagen<br />
bescherte <strong>de</strong>m<br />
Unternehmen in <strong>de</strong>r jüngeren Vergangenheit<br />
mehrere beachtenswerte Aufträge.<br />
Die hierfür eingesetzten Rollenherdöfen<br />
nutzen neben <strong>de</strong>r Hicon-<br />
Technologie eine ebenfalls im Labor<br />
von Ebner entwickelte Quenchtechnologie,<br />
die auch die erfor<strong>de</strong>rliche<br />
Trocknung einschließt. Da es sich<br />
bei <strong>de</strong>n Endprodukten zumeist um<br />
Platten und Bleche für die Luft- und<br />
Raumfahrt han<strong>de</strong>lt, wer<strong>de</strong>n die Anlagen<br />
nach <strong>de</strong>r strengen Luftfahrtnorm<br />
AMS 2750 D ausgelegt. Diese for<strong>de</strong>rt,<br />
dass die Temperatur im Ofen (furnace<br />
class 1) während <strong>de</strong>r Haltezeit an <strong>de</strong>n<br />
bei<strong>de</strong>n Grenztemperaturen nur um<br />
+/- 3 o K abweicht.<br />
Vor kurzem in Betrieb genommen<br />
wur<strong>de</strong>n die Rollenherdöfen für OAO<br />
KUMZ in Kamensk Uralski sowie für<br />
Alcoa OAO in Belaja Kalitva, bei<strong>de</strong> in<br />
Russland. Die Plattendicken betragen<br />
11 bis 150 mm bei einer beheizten<br />
Ofenlänge von 31,5 m bzw. 6 bis 200<br />
mm bei 36 m beheizter Ofenlänge.<br />
Auch westeuropäische Werke haben<br />
sich für Rollenherdöfen von Ebner<br />
entschie<strong>de</strong>n. Amag rolling GmbH in<br />
Österreich erhielt eine weitere Anlage<br />
für Plattendicken von 15 bis 100<br />
mm bei einer beheizten Ofenlänge<br />
von 9,9 m, mit <strong>de</strong>r Möglichkeit, die<br />
Anlage um eine weitere Zone zu verlängern.<br />
Für Aleris in Duffel, Belgien,<br />
wur<strong>de</strong> eine Anlage für Plattendicken<br />
von 3 bis 150 mm bei einer beheizten<br />
Ofenlänge von 19,8 m in Betrieb genommen.<br />
Das Ergebnis in all diesen<br />
Fällen: bestmögliche Planheit, beschädigungsfreie<br />
Oberflächen und<br />
einwandfreie Gefügestrukturen <strong>de</strong>r<br />
vergüteten Platten.<br />
Gera<strong>de</strong> auf <strong>de</strong>m Gebiet <strong>de</strong>r Wärmebehandlung<br />
von <strong>Alu</strong>miniumplatten<br />
konnte Ebner duch die Forschungsmöglichkeiten<br />
im betriebseigenen<br />
Großlabor einen wichtigen Beitrag<br />
zur Produkt- und Produktionsverbesserung<br />
liefern. Durch die innovativen<br />
Maßnahmen <strong>de</strong>r F&E-Abteilung<br />
konnten in enger Zusammenarbeit<br />
mit <strong>de</strong>n Anwen<strong>de</strong>rn völlig neu entwickelte<br />
Konzepte realisiert wer<strong>de</strong>n,<br />
die auf mo<strong>de</strong>rnste Qualitäts- und Leistungsanfor<strong>de</strong>rungen<br />
von Hightech-<br />
Produzenten und <strong>de</strong>ren Produkte<br />
zugeschnitten sind.<br />
In diesem Zusammenhang mel<strong>de</strong>t<br />
Ebner die erstmalige Lieferung einer<br />
Rollenherdofenanlage: nicht, wie bisher<br />
üblich, zur Wärmebehandlung<br />
von <strong>Alu</strong>miniumplatten, son<strong>de</strong>rn von<br />
Profilen aus <strong>Alu</strong>miniumlegierungen.<br />
Die für Aleris in Duffel bestimmte<br />
Anlage ist für die über <strong>de</strong>n gesamten<br />
Querschnitt verzugfreie Wärmebehandlung<br />
von komplexen Strangpressprofilen<br />
mit maximalen Außenmaßen<br />
250 x 560 mm und einer Länge von<br />
13 m vorgesehen,<br />
die im<br />
Fahrzeug- und<br />
Flugzeugbau<br />
zur Anwendung<br />
kommen.<br />
Dieser Ofen<br />
stellt eine echte<br />
Innovation<br />
dar, bei <strong>de</strong>ren<br />
Realisierung<br />
das Labor von<br />
Ebner in enger<br />
Zusammenarbeit<br />
mit <strong>de</strong>m<br />
Kun<strong>de</strong>n seine<br />
weitreichen<strong>de</strong>n Möglichkeiten einbringen<br />
konnte. Die bisherige vertikale<br />
Ofenbauweise mit all ihren Einschränkungen<br />
wird hier durch eine<br />
Horizontalanlage ersetzt.<br />
Kammeröfen mit Rechenmo<strong>de</strong>ll<br />
für optimalen Glühzyklus<br />
Auch bei dieser Produktlinie sucht<br />
Ebner die Marktnische von technologisch<br />
anspruchsvollen Anwendungen,<br />
Market lea<strong>de</strong>r for<br />
pusher-type furnaces<br />
Consi<strong>de</strong>r the example of pusher-type<br />
furnaces for rolling ingots: with 35<br />
units built all over the world over<br />
the past 20 years, Ebner is the market<br />
lea<strong>de</strong>r in this field. Pusher-type<br />
furnaces are used for homogenising<br />
and heating rolling ingots weighing<br />
up to 30 tonnes and measuring up to<br />
8650 x 2200 x 650 mm, to their rolling<br />
temperature. The shortest possible<br />
heating times with a maximum<br />
temperature difference of 6°K over<br />
the whole charge are achieved by<br />
the application of Hicon technology.<br />
Besi<strong>de</strong>s two pusher-type furnaces already<br />
commissioned at the new rolling<br />
plant of Yantai Nanshan in China,<br />
Ebner is also to <strong>de</strong>liver three more to<br />
China for Asia <strong>Alu</strong>minium and two for<br />
the new high-gra<strong>de</strong> strip rolling plant<br />
of Xiamen Xiashun. In Russia too new<br />
pusher-type furnaces by Ebner are in<br />
use, in particular at Alcoa in the Samara<br />
works.<br />
High expectations for the revival of<br />
the North American market are linked<br />
by Ebner to a new contract from Alcoa<br />
Rigid Packaging in Knoxville, Tennes-<br />
Rollenherdofenanlage bei <strong>de</strong>r AMAG rolling GmbH in Österreich<br />
Roller hearth furnace unit at AMAG rolling GmbH, Austria<br />
see. The two furnaces which will begin<br />
operating in autumn 2008 can take up<br />
to 48 ingots, corresponding to 1,200<br />
tonnes, and are therefore the largest of<br />
their type in the world. Alcoa expects<br />
a pay-back time of only a few years<br />
for this investment, not only because<br />
of improved quality and lower maintenance<br />
costs, but above all because<br />
of Ebner’s guarantee of high energy<br />
efficiency set against the enormously<br />
increased energy prices.<br />
68 ALUMINIUM · 1-2/2008
Tempering of aluminium plates<br />
and sheets: heat treatment in<br />
the limiting range<br />
The investment boom in plate production<br />
plants created by the aviation<br />
industry has in the recent past<br />
secured a number of notable or<strong>de</strong>rs<br />
for Ebner. Besi<strong>de</strong>s Hicon technology<br />
the roller hearth furnaces used for this<br />
employ quenching technology also<br />
<strong>de</strong>veloped in the company’s laboratories,<br />
which also inclu<strong>de</strong>s the necessary<br />
drying. Since the end products<br />
are mostly plates and sheets for use<br />
in aerospace, the plant is <strong>de</strong>signed in<br />
accordance with the strict AMS 2750<br />
D aviation standard, which <strong>de</strong>mands<br />
that in a Class 1 furnace the temperature<br />
may only <strong>de</strong>viate at the two limit<br />
values by no ore than ± 3°K.<br />
Recently commissioned were the<br />
roller hearth furnaces for OAO KUMZ<br />
in Kamensk Uralski and Alcoa OAO<br />
in Belaja Kalitva, both in Russia. �<br />
PROFHAL entwickelt, fertigt<br />
und vere<strong>de</strong>lt hochwertige<br />
<strong>Alu</strong>minium-Profil-System-<br />
Komponenten für<br />
unterschied lichste<br />
Anwendungsgebiete.<br />
INDIVIDUELLE LÖSUNGEN<br />
AUS ALUMINIUM<br />
ALUMINIUM · 1-2/2008<br />
bei <strong>de</strong>nen in zunehmen<strong>de</strong>m Maße die<br />
Luftfahrtnormen zur Anwendung kommen.<br />
Dazu zählen auch die an Aleris<br />
Koblenz gelieferten Kammeröfen zum<br />
Glühen und Altern von Platten für die<br />
Flugzeugindustrie, wobei die zuletzt<br />
gelieferte Anlage für zukünftige Plattenlängen<br />
von 34 m und eine maximale<br />
Charge von 150 Tonnen bezüglich<br />
<strong>de</strong>r gefor<strong>de</strong>rten Temperaturgleichmäßigkeit<br />
hervorzuheben ist, die weit<br />
unterhalb <strong>de</strong>r von <strong>de</strong>r Luftfahrt bisher<br />
gefor<strong>de</strong>rten Toleranzen liegt.<br />
Die bei Ebner im Laufe <strong>de</strong>r Jahre<br />
über viele Versuchsreihen angelegten<br />
Datenbanken über Temperaturverläufe<br />
bei <strong>de</strong>n unterschiedlichen <strong>Alu</strong>miniumlegierungen<br />
sind die Basis für<br />
eine Spitzenpositionierung bei <strong>de</strong>r<br />
Entwicklung von Rechenmo<strong>de</strong>llen.<br />
Übertragen auf die Produktionsanlagen<br />
steuern sie mit hoher Zuverlässigkeit<br />
die Temperaturführung während<br />
<strong>de</strong>s gesamten Wärmebehandlungsvorgangs.<br />
Erwähnenswert ist in die-<br />
MARKETS AND TECHNOLOGY<br />
sem Zusammenhang <strong>de</strong>r Einsatz <strong>de</strong>s<br />
von Ebner für Einzelbundöfen entwickelten<br />
Rechenmo<strong>de</strong>lls „BOS“ (Batch<br />
Furnace Optimization System), das<br />
erstmals auch bei einem Mehrbund-<br />
Kammerofen angewen<strong>de</strong>t wur<strong>de</strong>.<br />
Das Rechenmo<strong>de</strong>ll ermittelt für die<br />
jeweiligen Bunddimensionen und<br />
Legierungen sowie <strong>de</strong>ren Glühparameter<br />
<strong>de</strong>n optimalen Glühzyklus. Die<br />
vorausberechneten Temperatur- und<br />
Zeitwerte wer<strong>de</strong>n laufend mit <strong>de</strong>n gemessenen<br />
Werten kontrolliert und bei<br />
Bedarf angepasst. Dies garantiert optimale<br />
metallurgische Eigenschaften<br />
und eine Reduktion <strong>de</strong>r Durchlauf-<br />
und somit <strong>de</strong>r Produktionszeit.<br />
Autor<br />
PROFHAL ALUMINIUM PROFIL<br />
BEARBEITUNG GMBH<br />
Ein Unternehmen <strong>de</strong>r<br />
HAARMANN-GRUPPE<br />
Dettenheimer Straße 30<br />
91781 Weißenburg<br />
Tel. 0 91 41/8 55 65-0<br />
www.profhal.<strong>de</strong><br />
Dipl.-Ing. Bernhard Rieth ist Marketingspezialist<br />
und freier Fachjournalist.<br />
Als Inhaber <strong>de</strong>r Marketing Xpertise Rieth<br />
in Meerbusch berät er Ausrüstungspartner<br />
<strong>de</strong>r NE-Metall-Halbzeugindustrie in Marketingfragen.<br />
69<br />
www.haarmann-gruppe.<strong>de</strong>
MARKETS AND TECHNOLOGY<br />
Stoßofenanlage bei Yantai Nanshan <strong>Alu</strong>minium in China<br />
Pusher-type furnace unit at Yantai Nanshan <strong>Alu</strong>minium, China<br />
The plate thicknesses range from 11<br />
to 150 mm in a furnace with a hot zone<br />
31.5 m in length, or 6 to 200 mm in<br />
one with a hot zone 36 m long, respectively.<br />
Plants in western Europe<br />
too have opted for roller hearth furnaces<br />
by Ebner. Amag rolling GmbH<br />
in Austria is getting another unit for<br />
plate thicknesses of 15 to 100 mm in<br />
a furnace hot zone 9.9 m long, with the<br />
possibility of extending the unit by an<br />
additional zone. For Aleris in Duffel,<br />
Belgium, a unit for plate thicknesses<br />
of 3 to 150 mm in a furnace hot zone<br />
19.8 m long has begun operating. The<br />
result in all these cases has been the<br />
best possible flatness, surfaces free<br />
from damage, and perfect metallurgical<br />
structures in the tempered plates.<br />
Precisely in the field of aluminium<br />
plate heat treatment and thanks<br />
to the research facilities in its own<br />
major laboratory, Ebner has been<br />
able to make important contributions<br />
towards product and production improvement.<br />
Thanks to the innovative<br />
activities of its R & D <strong>de</strong>partment and<br />
in close collaboration with customers,<br />
completely new concepts have been<br />
<strong>de</strong>veloped which are tailor-ma<strong>de</strong> for<br />
the most mo<strong>de</strong>rn quality and performance<br />
<strong>de</strong>mands ma<strong>de</strong> by high-tech<br />
manufacturers and their products.<br />
In this connection Ebner has announced<br />
the first <strong>de</strong>livery of a roller<br />
hearth furnace unit, not as previously<br />
usual for the heat treatment of aluminium<br />
plates, but instead for that of aluminium<br />
alloy sections. The plant, <strong>de</strong>stined<br />
for Aleris in Duffel, is <strong>de</strong>signed<br />
for the heat treatment of complex ex-<br />
tru<strong>de</strong>d sections<br />
with maximum<br />
overall dimensions<br />
of 250 x<br />
560 mm and<br />
a length of 13<br />
m, all over the<br />
cross-section<br />
without any<br />
distortion or<br />
warping. These<br />
are inten<strong>de</strong>d for<br />
use in automotive<br />
and aircraft<br />
engineering.<br />
The furnace is<br />
a real innovation,<br />
for whose<br />
realisation the Ebner laboratory collaborated<br />
closely with the customer<br />
by providing its far-reaching possibilities.<br />
The previous, vertical furnace<br />
structure with all its limitations<br />
is in this case replaced by a horizontal<br />
unit.<br />
Chamber furnaces with a<br />
computed mo<strong>de</strong>l for<br />
optimal annealing cycles<br />
In this product line too Ebner has<br />
sought to serve the market niche of<br />
technologically sophisticated applications,<br />
for which the aviation standards<br />
are applied to an ever-increasing<br />
extent. These also inclu<strong>de</strong> the<br />
chamber furnaces supplied to Aleris<br />
Koblenz for annealing and ageing<br />
plates for the aircraft industry. In relation<br />
to the temperature uniformity<br />
<strong>de</strong>man<strong>de</strong>d, it should be stressed that<br />
the unit recently <strong>de</strong>livered for future<br />
plate lengths of 34 m and a maximum<br />
charge of 150 tonnes achieves results<br />
far below the tolerances <strong>de</strong>man<strong>de</strong>d<br />
for aviation until now.<br />
The database compiled by Ebner<br />
over the years on temperature variations<br />
in the various aluminium alloys,<br />
which are the fruit of numerous test<br />
series, are the basis for achieving a<br />
peak position in the <strong>de</strong>velopment of<br />
computed mo<strong>de</strong>ls. When transferred<br />
to the production units these ensure<br />
very reliable control of the temperature<br />
management throughout the heat<br />
treatment process. In this connection<br />
it is worth mentioning Ebner’s use<br />
of the computed mo<strong>de</strong>l ‘BOS’ (Batch<br />
Furnace Optimisation System) <strong>de</strong>veloped<br />
by the company itself for<br />
single-coil furnaces, which was for<br />
the first time used also for a multicoil<br />
chamber furnace. The computer<br />
mo<strong>de</strong>l <strong>de</strong>termines the optimum annealing<br />
cycle for the coil dimensions<br />
and alloy concerned, and the annealing<br />
parameters required. The pre-calculated<br />
temperature and time values<br />
are continuously checked against the<br />
measured values and adaptations are<br />
ma<strong>de</strong> as necessary. This ensures optimum<br />
metallurgical properties and<br />
speeds up the throughput and hence<br />
the production time.<br />
Author<br />
Ebner Industrieofenbau – facts & figures<br />
Dipl.-Ing. Bernhard Rieth is a marketing<br />
<strong>special</strong>ist and freelance technical journalist.<br />
As proprietor of Marketing Xpertise<br />
Rieth in Meerbusch he advises equipment<br />
partners of the NF-metal semis industry on<br />
marketing-related issues.<br />
Founding year 1948<br />
Main product lines Bell annealing furnaces, strip annealing furnaces,<br />
pusher-type furnaces, floater-type furnaces,<br />
roller hearth furnaces, chamber furnaces<br />
Total turnover 150 million euros<br />
Manufacturing locations<br />
Linz, Austria<br />
Wadsworth, Ohio/USA<br />
Taicang, P.R. China<br />
Employment<br />
750<br />
60<br />
120<br />
Additional service stations Japan, Taiwan<br />
Industries served<br />
Steel<br />
<strong>Alu</strong>minium<br />
Copper & Cu-alloys<br />
Turnover in percent<br />
70%<br />
25%<br />
5%<br />
Annual R & D expenditure At present: 5 to 6 percent of turnover<br />
In future: 8 percent of turnover<br />
70 ALUMINIUM · 1-2/2008
Peter H. Ebner: “The <strong>de</strong>cisive factor<br />
for our success is the high<br />
quality standards we insist upon”<br />
Robert Ebner: “In the coming<br />
years we intend to increase<br />
our research and <strong>de</strong>velopment<br />
expenditure to eight percent of<br />
turnover”<br />
“We <strong>de</strong>ci<strong>de</strong> the<br />
competition in<br />
terms of quality”<br />
Interview with Peter H. Ebner and<br />
Robert Ebner, CEO of Ebner<br />
Industrieofenbau GmbH<br />
ALUMINIUM: Mr. Ebner, for products<br />
such as Hicon / H 2 bell annealing furnaces<br />
your company has <strong>de</strong>veloped to<br />
become the undisputed world market<br />
lea<strong>de</strong>r, and for other furnace types<br />
you are one of the top suppliers. To<br />
what do you attribute your outstanding<br />
position among international furnace<br />
manufacturers?<br />
Peter Ebner: The <strong>de</strong>cisive factor for<br />
our success is the high quality standards<br />
we insist upon, and from which<br />
we will not <strong>de</strong>viate at any price. Even<br />
if we occasionally miss the mark and<br />
do not get a chance. Ebner’s focus is<br />
ALUMINIUM · 1-2/2008<br />
the customer and his <strong>special</strong> technical<br />
requirements. Our aim is to offer him<br />
the technically optimum solution for<br />
his needs.<br />
ALUMINIUM: With no thought of<br />
price in this?<br />
P. Ebner: We are aware that our prices<br />
are at or near the top of the range. We<br />
cannot and do not wish to win or<strong>de</strong>rs<br />
by aggressive price competition.<br />
Rather, we look to establish a fair partnership<br />
with our customers, to whom<br />
we offer tailor-ma<strong>de</strong> plant solutions<br />
which work absolutely reliably for a<br />
long time. That cannot be done for<br />
bargain prices. When one looks not<br />
just purely at the purchase price of a<br />
unit but also at its long-term economy,<br />
we have no reason to fear competition<br />
from elsewhere.<br />
ALUMINIUM: Let us focus on the<br />
economic aspect. What are your main<br />
thoughts about that where a furnace<br />
is concerned?<br />
Robert Ebner: An essential criterion<br />
which is becoming continually more<br />
important is the energy-efficiency of<br />
our furnaces. I refer here to our Hicon<br />
technology, with which we equip all<br />
our furnaces. For example, at present<br />
we are building two pusher-type furnaces<br />
for our long-term customer<br />
Alcoa in the USA – in fact, the largest<br />
of their kind built anywhere in<br />
the world. Thanks to the substantially<br />
more efficient use of energy that is<br />
possible today compared with existing<br />
box furnaces, and also to their low<br />
maintenance needs, the customer’s<br />
pay-back time on the investment will<br />
amount to only a few years.<br />
ALUMINIUM: How much importance<br />
do you attach to the international<br />
orientation of your company with<br />
its facilities in Austria, the USA and<br />
China?<br />
P. Ebner: Ebner was foun<strong>de</strong>d in Linz<br />
sixty years ago by my father. That is<br />
still the headquarters and technical<br />
centre for our company’s know-how.<br />
Our American plant in Wadsworth,<br />
Ohio, was established in 1987. Our<br />
aim was to gain a foothold in the dollar<br />
area. From Wadsworth we serve<br />
the North American market and the<br />
regions that operate with US dollars.<br />
For Ebner, business in America grew<br />
rapidly until 1999. In the USA we<br />
sometimes even achieved a turnover<br />
MARKETS AND TECHNOLOGY<br />
fraction of almost fifty percent of all<br />
our business.<br />
ALUMINIUM: How is that plant justified<br />
today in view of the investment<br />
slump of the steel and NF industries<br />
there, which has lasted for some<br />
years?<br />
P. Ebner: Even through hard times<br />
I have continued believing in our<br />
commitment in America. Without a<br />
presence in the dollar area the region<br />
cannot be served, as is shown all too<br />
clearly now by the present weakness<br />
of the dollar.<br />
ALUMINIUM: So will you continue<br />
operating in America?<br />
R. Ebner: Of course. In the USA there<br />
are many furnaces which have been<br />
operating since the late forties or early<br />
fifties and which, in view of the high<br />
cost of energy, must now be replaced<br />
by mo<strong>de</strong>rn, energy-saving units.<br />
ALUMINIUM: Let us now look at the<br />
most dynamic economic area of all:<br />
how do you assess <strong>de</strong>velopment in<br />
Asia?<br />
P. Ebner: Our Asian business has been<br />
growing bit by bit for many years, and<br />
we have approached that market in<br />
small, well-prepared steps. After initially<br />
gaining a presence with servicing<br />
stations in Japan and Taiwan, it<br />
became increasingly clear as the years<br />
passed that we nee<strong>de</strong>d a production<br />
base of our own in Asia.<br />
R. Ebner: To begin with, we looked for<br />
suitable locations in South Korea. It is<br />
true that Korea would have had the<br />
necessary infrastructure, but it was<br />
very expensive. Thailand would have<br />
been suitable in terms of living conditions<br />
for our Austrian employees,<br />
but there the environment was not<br />
right. At the end of the day we opted<br />
for China. We had many preliminary<br />
talks to clarify location-related questions<br />
such as: what are the stumbling<br />
blocks, where is there an appropriate<br />
industrial estate, etc. Finally, in 2002<br />
we <strong>de</strong>ci<strong>de</strong>d to build a plant of our own<br />
in Taicang, near Shanghai, where we<br />
recently completed the fourth expansion<br />
stage.<br />
ALUMINIUM: How free were you in<br />
your <strong>de</strong>cision-making?<br />
P. Ebner: What we built up in Taicang<br />
was created without any restrictions<br />
on the part of Chinese authorities.<br />
In any case it is not a joint �<br />
71
MARKETS AND TECHNOLOGY<br />
venture, but a company wholly owned<br />
by Ebner. I would not have gone to<br />
China if it had been necessary to set<br />
up a joint venture there with a Chinese<br />
partner.<br />
ALUMINIUM: What experiences can<br />
you pass on to others who are faced<br />
with similar <strong>de</strong>cisions?<br />
P. Ebner: Our USA project taught<br />
us that we could not rely purely on<br />
American staff, but that at least for<br />
some years we had to send across<br />
highly qualified technical personnel<br />
from Linz. Precisely for a company<br />
such as Ebner which sets great store<br />
by quality, that is unavoidable. The<br />
commitment of technicians from Linz<br />
on the basis of three- to five-year contracts<br />
was <strong>de</strong>cisive in ensuring that<br />
both qualitatively<br />
and in terms of<br />
production figures,<br />
the plant attained<br />
satisfactory levels<br />
within two years.<br />
R. Ebner: The learning<br />
curve we travelled<br />
in the USA in<br />
our first years there,<br />
we could then avoid<br />
in China. From<br />
the beginning, the<br />
new production<br />
management and<br />
quality monitoring<br />
were in the hands<br />
of senior staff from<br />
our parent plant in<br />
Austria. Of course, that is not to belittle<br />
the importance of our Chinese<br />
employees, who have to <strong>de</strong>al with<br />
‘China-internal’ issues.<br />
ALUMINIUM: It must surely have<br />
been an enormous challenge for a<br />
medium-sized company to do without<br />
some of its <strong>special</strong>ists at the parent<br />
plant.<br />
P. Ebner: Quite right, but there was<br />
no other way to guarantee our high<br />
quality standards – which for us, is<br />
indispensable.<br />
ALUMINIUM: Do you perceive signs<br />
that India’s steel and NF-metal industries<br />
will soon be following in China’s<br />
footsteps and so catching up?<br />
R. Ebner: In our estimation China has<br />
moved far ahead of India in terms of<br />
infrastructure and the quality of life of<br />
personnel in recent years. It is true that<br />
India has the major advantage of using<br />
the English language, but the progress<br />
of its infrastructure is slow. Nevertheless,<br />
India is a very important growth<br />
market with a steadily expanding<br />
middle class, with many ‘consumers’,<br />
who stimulate the economy. India is<br />
becoming continually more important<br />
for us Europeans, but its <strong>de</strong>velopment<br />
will not be as rapid as in China.<br />
P. Ebner: To return to our plant in China:<br />
we are naturally very interested<br />
in exporting from Taicang to the surrounding<br />
Asian countries, including<br />
India for at least the past year, where<br />
we are at present carrying out some<br />
major assembly projects. We provi<strong>de</strong><br />
the less expensive parts of furnaces<br />
Ebner laboratory at Leonding<br />
from Taicang – at prices that are very<br />
acceptable in India.<br />
ALUMINIUM: That raises the question:<br />
what do you now still produce<br />
in Linz?<br />
P. Ebner: Here in Linz we make all<br />
the components that are quality-critical<br />
for our business and which, if they<br />
were to be copied, would threaten the<br />
future of our company. Thus, so long<br />
as there is still no effective copyright<br />
or patent law in China, we will supply<br />
such know-how-rich components<br />
from Linz.<br />
ALUMINIUM: So how do you divi<strong>de</strong><br />
the production between your three<br />
plants?<br />
R. Ebner: We have analysed our various<br />
furnace types and split them into<br />
A-, B- and C-components. A-compo-<br />
nents are ma<strong>de</strong> only in Austria or the<br />
USA, B-components at all three locations,<br />
while because of labour costs<br />
it makes sense to produce C-components<br />
only in China.<br />
In the 1990s we resisted pressure<br />
from several customers who wanted<br />
us to produce key-components of our<br />
units – for example the bases of our<br />
bell annealing furnaces – in China as<br />
well. We strictly refused to do that,<br />
even at the risk of no longer receiving<br />
any or<strong>de</strong>rs. This led to four or five relatively<br />
slack years when we got fewer<br />
or<strong>de</strong>rs for bell annealing furnaces, until<br />
finally things changed again. Today,<br />
it is more of a selling-point for our furnaces<br />
that the core of our units come<br />
from Linz or the USA.<br />
ALUMINIUM:<br />
What other functions<br />
have you concentrated<br />
in Linz?<br />
R. Ebner: Our company<br />
philosophy<br />
is to do all the research<br />
in our laboratory<br />
in Austria,<br />
because the experience<br />
from all<br />
our plants comes<br />
together here and<br />
we do not want to<br />
operate a two-track<br />
system. Whether in<br />
good years or bad,<br />
we invest five to six<br />
percent of turnover<br />
in research and <strong>de</strong>velopment. That<br />
is already a high proportion and in<br />
the coming years we even intend to<br />
increase it to eight percent. We are<br />
convinced that to secure the future of<br />
our company this is vitally important.<br />
Among other things we want to enlarge<br />
our laboratory.<br />
ALUMINIUM: What are the laboratory’s<br />
main tasks?<br />
P. Ebner: Consi<strong>de</strong>r for example the<br />
support of sales: quite often a customer<br />
comes to us because he cannot<br />
achieve the necessary product quality<br />
with his existing equipment. Nobody<br />
who comes to Ebner has to base<br />
his purchasing <strong>de</strong>cisions on written<br />
guarantee values alone. Instead, we<br />
can <strong>de</strong>monstrate the quality guarantee<br />
we give using our own equipment.<br />
72 ALUMINIUM · 1-2/2008
For this, as a rule we work with test<br />
equipment on a one-to-ten scale and<br />
occasionally, for certain problems,<br />
with full-size units – for example the<br />
annealing of coil batches. We fit these<br />
with thermocouples all over, anneal<br />
and heat treat them in the presence of<br />
the customer, and he can then inspect<br />
the analyses himself or send them on<br />
to his own buyer.<br />
It is important that in our research<br />
we tend to and optimise the dovetailing<br />
and interplay of all the individual<br />
plant components. For example, we<br />
have long been <strong>de</strong>veloping our own<br />
burner technology because we do not<br />
want to rely on others for important<br />
plant components.<br />
ALUMINIUM: Has the <strong>de</strong>velopment<br />
potential for furnaces not now been<br />
largely exhausted?<br />
R. Ebner: I do not believe so. As an<br />
ALUMINIUM · 1-2/2008<br />
example: in the case of bell annealing<br />
furnaces for steel coils, which with<br />
their hydrogen technology and high<br />
convection we have been selling very<br />
successfully for some thirty years, we<br />
have meanwhile arrived at the sixth<br />
generation. In this, we have boosted<br />
furnace performance by forty to fifty<br />
percent, whereas the price has moved<br />
downwards. Such <strong>de</strong>velopment can<br />
only be achieved with a laboratory of<br />
one’s own.<br />
P. Ebner: Another thing that must not<br />
be un<strong>de</strong>restimated: to help us remain<br />
an attractive employer the laboratory<br />
is a very important factor. That<br />
is where the technical staff can try<br />
out their own i<strong>de</strong>as, and this has so<br />
often been to our benefit, while in the<br />
meantime we have formed an international<br />
thirty-man team.<br />
ALUMINIUM: So the laboratory plays<br />
Siemens liefert Fertigstraße für<br />
<strong>Alu</strong>minium-Warmwalzwerk nach China<br />
Siemens Metals Technologies hat von<br />
<strong>de</strong>r Chinalco <strong>Alu</strong>minium <strong>de</strong>n Auftrag<br />
über die mechanische und elektrische<br />
Ausrüstung einer neuen Fertigstraße<br />
mit Zwillingshaspel erhalten. Das<br />
Warmwalzwerk wird bei <strong>de</strong>r Chinalco<br />
Ruimin in Mawei/Fuzhou, Provinz<br />
Fukien, errichtet. Das Auftragsvolumen<br />
beträgt rund 20 Mio. Euro. Das<br />
erste <strong>Alu</strong>miniumband soll im September<br />
2009 gewalzt wer<strong>de</strong>n. Die<br />
Fertigstraße ist Teil eines geplanten<br />
neuen Warmwalzwerkes, das im Zuge<br />
eines großangelegten Ausbauprojekts<br />
von Chinalco Ruimin in <strong>de</strong>n nächsten<br />
Jahren errichtet wer<strong>de</strong>n soll. Das<br />
Vorgerüst und <strong>de</strong>r vertikale Staucher<br />
wer<strong>de</strong>n von einem lokalen Lieferanten<br />
mit technischer Unterstützung<br />
von Siemens beigestellt.<br />
Die zu liefern<strong>de</strong> Fertigstraße umfasst<br />
ein Quarto-Gerüst mit automatischer<br />
hydraulischer Walzspaltregelung<br />
sowie positiver und negativer<br />
Arbeitswalzenbiegung. Das Warmwalzwerk<br />
wird über eine Kapazität<br />
von 270.000 Jahrestonnen verfügen<br />
und ist für Bän<strong>de</strong>r mit Breiten<br />
MARKETS AND TECHNOLOGY<br />
a major part among the factors that<br />
contribute to your success …<br />
P. Ebner: … as also does the low<br />
fluctuation level of our employment<br />
structure. We have people who already<br />
represent the third generation<br />
that has worked for Ebner. They often<br />
come to us as apprentices and stay on<br />
at Ebner all their working life. Every<br />
year we train twenty apprentices, and<br />
we have also adopted in America the<br />
same apprentice training as in Linz.<br />
We also offer our most able employees<br />
the chance to attend engineering<br />
college in the evenings and become<br />
more highly trained. We then place<br />
such employees in the laboratory, the<br />
<strong>de</strong>sign and construction <strong>de</strong>partments,<br />
or in sales.<br />
ALUMINIUM: Mr. Peter and Mr. Robert<br />
Ebner, many thanks for this discussion.<br />
Siemens supplies new<br />
aluminum hot finishing mill to China<br />
Siemens Metals Technologies has<br />
received an or<strong>de</strong>r from Chinalco<br />
<strong>Alu</strong>minium Co., Ltd, to supply the<br />
mechanical and electrical equipment<br />
for a new hot aluminium twin coiling<br />
finishing mill. The plant will be built<br />
at Chinalco Ruimin at Mawei/Fuzhou<br />
in Fujian province. The or<strong>de</strong>r volume<br />
is around 20 million euros; production<br />
of the first coil is scheduled for<br />
September 2009. This mill will form<br />
a key part of a proposed new aluminium<br />
1+1 hot line, which is the key<br />
process component of a major plant<br />
expansion planned by Ruimin. The<br />
roughing stand and the vertical edger<br />
will be built by a local supplier with<br />
technical support by Siemens.<br />
The finishing mill will comprise a<br />
4-high stand equipped with hydraulic<br />
automatic gauge control and positive<br />
and negative bending. The mill itself<br />
will be <strong>de</strong>signed to roll a wi<strong>de</strong> range<br />
of products and alloys, and will be capable<br />
of rolling over 270,000 tonnes<br />
per year at widths in excess of 2.2<br />
metres. In addition to the mechanical<br />
equipment, Siemens is also supplying<br />
the entire automation system and the<br />
drive systems as well as the process<br />
automation system for the complete<br />
hot line. All the components and systems<br />
used are part of ‘Siroll <strong>Alu</strong>’, the<br />
integrated solution for aluminium hot<br />
mills.<br />
UK facilities become Competence<br />
Centre for plate rolling mills and<br />
aluminium plants<br />
Siemens Metals Technologies has<br />
combined its two UK locations in<br />
Sheffield and Christchurch into the<br />
<strong>special</strong> subdivision ‘Plate & <strong>Alu</strong>minium<br />
Rolling’, which will be responsible<br />
for the worldwi<strong>de</strong> business<br />
� �<br />
73
MARKT UND TECHNIK<br />
von mehr als 2,2 Meter ausgelegt.<br />
Neben <strong>de</strong>r mechanischen Ausrüstung<br />
liefert Siemens das komplette Automatisierungssystem<br />
und die Antriebstechnik,<br />
außer<strong>de</strong>m die Prozessautomatisierung<br />
für das gesamte Warmwalzwerk.<br />
Alle eingesetzten Systeme<br />
und Komponenten sind Bestandteil<br />
von „Siroll <strong>Alu</strong>“, <strong>de</strong>r integrierten Lösungsplattform<br />
vom Siemens für <strong>Alu</strong>minium-Warmwalzwerke.<br />
Britischer Standort wird Kompetenzcenter<br />
für Grobblech-Walzstraßen<br />
und <strong>Alu</strong>miniumanlagen<br />
Siemens Metals Technologies hat<br />
seine bei<strong>de</strong>n britischen Standorte<br />
Sheffield und Christchurch zu <strong>de</strong>m<br />
Geschäftszweig „Plate and <strong>Alu</strong>minium<br />
Rolling” zusammengefasst, in<br />
<strong>de</strong>m künftig das weltweite Geschäft<br />
mit Grobblech- und <strong>Alu</strong>miniumwalzstraßen<br />
betrieben wird. Der steigen<strong>de</strong><br />
Bedarf an Grobblechen beflügele auch<br />
das Anlagengeschäft mit Walzstraßen,<br />
sagte Hans-Werner Linne, Leiter <strong>de</strong>s with plate and aluminium rolling<br />
neuen Geschäftszweiges.<br />
mills. The growing <strong>de</strong>mand for heavy<br />
Während vor allem in China, Indien plate was also boosting project busi-<br />
und Russland <strong>de</strong>r Neubau von Anlaness with rolling mills, Hans-Werner<br />
gen geplant wird, liegt <strong>de</strong>r Schwer- Linne, head of the new subdivision,<br />
punkt in Europa und Nordamerika said.<br />
auf <strong>de</strong>r Mo<strong>de</strong>rnisierung, um durch There are plans to construct new<br />
die Leistungssteigerung bestehen<strong>de</strong>r plants, e<strong>special</strong>ly in China, India and<br />
Anlagen die wachsen<strong>de</strong> Nachfrage zu Russia, whereas, in Europe and North<br />
befriedigen. Dies lässt sich jedoch nur America, the focus is on mo<strong>de</strong>rnisa-<br />
mit <strong>de</strong>m Ausbau <strong>de</strong>s Serviceangebots tion. Here, improving the perform-<br />
erreichen. Um das Angebot zu erweiance of existing plants is supposed<br />
tern, wur<strong>de</strong> daher die Plate Mill Con- to satisfy rising <strong>de</strong>mand. This will<br />
sulting Group in Sheffield gegrün<strong>de</strong>t. involve expansion in the scope of<br />
Im Mo<strong>de</strong>rnisierungsgeschäft ver- maintenance solutions on offer as<br />
fügt <strong>de</strong>r neue Geschäftszweig Siemens well as a wi<strong>de</strong>r range of services for<br />
zufolge weltweit über einen Marktan- plant mo<strong>de</strong>rnisation. To this end, a<br />
teil von 48 Prozent bei <strong>Alu</strong>minium- Plate Mill Consulting Group was set<br />
anlagen. Schon heute, in einer Zeit up in Sheffield.<br />
boomen<strong>de</strong>r Neuanlagen-Projekte, According to Siemens the new busi-<br />
will sich Siemens mit dieser Strategie ness unit has global shares of 48% in<br />
auf neue Marktgegebenheiten künf- mo<strong>de</strong>rnising of aluminium mills. The<br />
tiger Jahre vorbereiten. „Mittelfristig task of the company is to take action in<br />
erwarten wir einen starken Anstieg a time of booming ‘greenfield’ projects<br />
<strong>de</strong>s Mo<strong>de</strong>rnisierungsgeschäftes”, so in or<strong>de</strong>r to a<strong>de</strong>quately prepare for the<br />
Linne.<br />
� market in the future.<br />
�<br />
<strong>Alu</strong>minium for building and construction in China<br />
Shi Lili, Beijing<br />
Chinas’s aluminium extrusion industry<br />
for building and construction<br />
took its first steps in 1980.<br />
In the 1990s China’s aluminium<br />
industry for building and construction<br />
moved into a new era<br />
featured by quality, variety, profits<br />
and product structure. Today China’s<br />
construction industry is the<br />
driving force of the growing <strong>de</strong>mand<br />
for aluminium products. In<br />
the long run aluminium products<br />
for construction will maintain the<br />
leading position in the aluminium<br />
extrusion industry.<br />
Brief history and status quo<br />
Although China had its own complete<br />
aluminium products extrusion line as<br />
early as 1956 when Northeast Light<br />
Alloys Company was set up, and also<br />
brought over eight hydraulic machines<br />
from Japan UBE Machinery<br />
in 1971, these units were all <strong>de</strong>voted<br />
to aluminium products for industrial<br />
use. China’s aluminium extrusion<br />
industry for building and construction<br />
took its first steps in March 1980<br />
when Guangzhou Dongjiao Yuncun<br />
<strong>Alu</strong>minium 6 th Plant was put into production.<br />
This was a joint venture be-<br />
tween Guangzhou 2 nd Light Industry<br />
<strong>Alu</strong>minium Products Company and<br />
China <strong>Alu</strong>minium Corporation, Hong<br />
Kong. Except for a melting furnace<br />
and the anodic oxidation treatment<br />
line, all other technologies <strong>de</strong>pen<strong>de</strong>d<br />
on Hong Kong and Taiwan. Also in<br />
74 ALUMINIUM · 1-2/2008<br />
All sources: Beijing Antaike
the same year, Liaoning Yingkou <strong>Alu</strong>minium<br />
Products Plant and Tianjin<br />
<strong>Alu</strong>minium Alloy Plant introduced<br />
16.3 MN hydraulic machines from Japan<br />
UBE Machinery. This means that<br />
China’s aluminium production for<br />
building and construction started in<br />
both Northern and Southern regions<br />
almost at the same time. In the middle<br />
of the 1980s China was un<strong>de</strong>rgoing<br />
its first boom of the aluminium<br />
extrusion industry. By 1986 China<br />
had 175 aluminium extrusion plants<br />
with 380 kt/a of production capacity<br />
and 400 extrusion machines. However,<br />
a cold snap followed since the<br />
country adopted policies to restrict<br />
aluminium products and application<br />
in building and construction<br />
that year and aluminium production<br />
accordingly dropped substantially.<br />
Yet another surge of aluminium<br />
products in China began from 1991<br />
to 1998 with <strong>de</strong>eper and more wi<strong>de</strong>spread<br />
influence than that of the mid<br />
1980s. All provinces except for Tibet<br />
had their own extrusion plants, including<br />
five in Hainan Province in<br />
the far south of China. There were<br />
1,142 plants in total with 4,000 extrusion<br />
machines and a total production<br />
capacity of 4,300 kt/a of at that time.<br />
Since then, China’s aluminium industry<br />
for building and construction has<br />
mo<strong>de</strong>rated the pursuit of quantity<br />
and moved into a new era featured<br />
by quality, variety, profits and product<br />
structure.<br />
After years of booming <strong>de</strong>velopment<br />
since 1999, the number of extrusion<br />
plants dropped below 600 and<br />
all five of the plants in Hainan were<br />
shut down, mainly because of increasingly<br />
intense competition among the<br />
market participants and aggravating<br />
market conditions. After 2000, China<br />
began to shift its strategy and put<br />
more effort into the ad<strong>de</strong>d value of<br />
aluminium products. Thus, production<br />
capacity increased at a lower rate<br />
of approximately 10 percent annually.<br />
By the end of 2005 the number of aluminium<br />
extrusion plants had fallen to<br />
650, with approximately 5,100 kt/a of<br />
production capacity and 3,000 extrusion<br />
machines, and China held first<br />
place in terms of number of companies,<br />
production capacity and total<br />
production.<br />
ALUMINIUM · 1-2/2008<br />
After years of adjustment of the<br />
product structure by the market, the<br />
number of extrusion plants has been<br />
on the <strong>de</strong>crease in recent years, yet<br />
total exports have gone up. In 2006<br />
alone total exports amounted to 68 kt<br />
or 45 percent of total world exports,<br />
making China the major aluminium<br />
production base in the world.<br />
By the end of 2006 China’s aluminium<br />
extrusion production reached<br />
4,500 kt/a, of which 80 percent was<br />
for building and construction. Advanced<br />
technologies and machines<br />
contributed a lot to this speedy <strong>de</strong>velopment.<br />
At present, many Chinese<br />
extrusion companies have invested in<br />
foreign equipment and technologies<br />
which helped Chinese enterprises,<br />
both state owned and private, to make<br />
fast progress. This also brought huge<br />
business opportunities for foreign<br />
machine manufacturers. According to<br />
statistics, so far China has introduced<br />
1,026 extrusion machines from other<br />
countries or regions, mainly from<br />
Taiwan and Japan since 1980, and<br />
this accounts for about 70 percent<br />
of the total. Out of this number, 446<br />
machines were for surface treatment,<br />
MARKETS AND TECHNOLOGY<br />
379 for coloured anodising, 86 for<br />
static spraying, 22 for fluorine carbon<br />
spraying, 91 for electrophoretic painting<br />
and 31 for wood treatment lines.<br />
Besi<strong>de</strong>s these, China also paid attention<br />
to the self innovation and its first<br />
7,500 t short-stroke extrusion machine<br />
was put into use in 2006. In the<br />
same year, China also ma<strong>de</strong> its first<br />
1,000 t reverse extrusion machine. Up<br />
to the present China owns 20 big extrusion<br />
machines of 5,000 to 12,500 t,<br />
including those already in use, being<br />
installed, or on or<strong>de</strong>r.<br />
The attractiveness of the Chinese<br />
market has also brought numerous<br />
suppliers of auxiliary equipment and<br />
materials into the country. E<strong>special</strong>ly<br />
with more recognition of Chinese aluminium<br />
products on the international<br />
market and wi<strong>de</strong>r applications, most<br />
market participants, both at home<br />
and abroad, approach China’s market<br />
with confi<strong>de</strong>nce.<br />
Present market situation<br />
China’s construction industry has<br />
been the driving force of the growing<br />
<strong>de</strong>mand for aluminium products. The<br />
75
MARKETS AND TECHNOLOGY<br />
main focus is on three aspects:<br />
• line-supporting poles and pylons,<br />
to reduce total weight<br />
• airplane runways, to increase<br />
flexibility<br />
• satisfying various <strong>de</strong>mands relating<br />
to house <strong>de</strong>coration.<br />
China’s apparent consumption of aluminium<br />
extrusion products grew by<br />
26.4 percent to 4,080 kt/a in 2006.<br />
Among this, aluminium products for<br />
building and construction account for<br />
almost 70 percent of the total. In 2006<br />
China’s production of automobiles,<br />
motorcycles, bicycles, household<br />
appliances, microelectronic<br />
computers,<br />
cell-phones, etc. increased<br />
at a headlong<br />
pace. Also since 2006,<br />
China’s civil aviation<br />
project was activated,<br />
railway transportation<br />
<strong>de</strong>veloped at a<br />
high rate and highspeed<br />
trains entered<br />
a new phase. All these<br />
sectors provi<strong>de</strong> good<br />
market prospects for<br />
extru<strong>de</strong>d aluminium<br />
products.<br />
Yet China’s use of aluminium for<br />
building and construction will continue<br />
to maintain the leading position,<br />
owing to the strong <strong>de</strong>velopment of<br />
China’s construction industry. In 2006<br />
alone, China’s house construction<br />
acreage reached 2.1 billion square<br />
meters, an increase of 21 percent<br />
compared with 2005.<br />
Construction acreage is the pioneer<br />
in<strong>de</strong>x for future aluminium production<br />
for building. On average, the<br />
house completion acreage has been<br />
growing at 4 percent each year from<br />
1995 to 2006. Between 2007 and 2010<br />
China’s real estate investment will<br />
grow at an average annual rate of over<br />
15 percent and the house completion<br />
acreage will increase by over 10 percent<br />
each year. Accordingly, <strong>de</strong>mand<br />
for aluminium products by China’s<br />
construction industry will increase by<br />
a constant 12 percent, corresponding<br />
to an additional <strong>de</strong>mand for aluminium<br />
of 500 kt/a per year.<br />
Statistics show that over 50 percent<br />
of China’s new houses are ma<strong>de</strong><br />
with aluminium door and window<br />
frames. One-third of every 10 million<br />
square meters of completed construction<br />
acreage each year involves<br />
aluminium products and each square<br />
meter consumes 15 kg of aluminium.<br />
Besi<strong>de</strong>s, pipelines, handrails, lad<strong>de</strong>rs,<br />
<strong>de</strong>coration parts, etc. also involve<br />
large quantities of aluminium products.<br />
In the long term, with China’s urbanization<br />
and industrialization in the<br />
years to come, China’s alumina consumption<br />
will continue to increase. It<br />
is forecast that aluminium products<br />
for building and construction will<br />
grow by eight to 15 percent, to 2,430<br />
kt/a, 2,720 kt/a and 2, 940 kt/a in<br />
2005, 2006 and 2007 respectively.<br />
Although aluminium extrusion is<br />
generally regar<strong>de</strong>d as an energy-intensive<br />
industry, the construction acreage<br />
increases by two billion square meters<br />
each year in China. On the basis that<br />
aluminium products for doors, windows<br />
and walls account for 30 percent<br />
of total construction materials,<br />
the prospects for aluminium for construction<br />
and building are quite promising<br />
in the future, granted the annual<br />
increase of about 25 to 30 percent in<br />
real estate investment. It is expected<br />
that with the coming Beijing Olympic<br />
Games in 2008 and the Shanghai<br />
World Expo in 2010, China’s <strong>de</strong>mand<br />
for aluminium construction products<br />
will stay above 3,200 kt/a until 2010.<br />
As for China’s <strong>de</strong>mand for aluminium<br />
consi<strong>de</strong>red sector by sector, the<br />
main products are generally aluminium<br />
sections, plates and foils, casting,<br />
wires, bars and poles. Consi<strong>de</strong>ring the<br />
example year of 2005, China’s total<br />
consumption of aluminium products<br />
in the construction sector was 2,680<br />
kt, of which 77 percent is for aluminium<br />
profiles.<br />
Future prospects<br />
China, as a large aluminium producer<br />
and consumer at present and in the<br />
future, has its own undisputed advantages<br />
in terms of market consumption<br />
and low production cost. Accordingly,<br />
some international aluminium companies<br />
have already or are planning<br />
to set up production bases in China.<br />
It is expected that the production capacity<br />
and total production of China’s<br />
aluminium extru<strong>de</strong>d<br />
products will grow by<br />
5.8 percent and 7.5<br />
percent respectively<br />
on average from 2007<br />
to 2010, and will reach<br />
6,890 kt/a and 5,520<br />
kt/a by 2010.<br />
It is predicted that<br />
China’s apparent aluminium<br />
consumption<br />
for building and construction<br />
will reach<br />
over 3,000 kt by 2010<br />
and will account for<br />
over 60 percent of total aluminium<br />
extrusion consumption. This percentage<br />
may be a little lower due to<br />
rising aluminium consumption for<br />
industrial use.<br />
Until now, the production and<br />
number of companies for aluminium<br />
products used in construction still<br />
maintains the dominant position in<br />
the overall aluminium extrusion industry<br />
in China. At present, over 480<br />
enterprises hold formal legal permits<br />
to produce aluminium products for<br />
building and most of them are privately<br />
owned, e<strong>special</strong>ly in Guangdong.<br />
In the long term aluminium products<br />
for construction will still maintain<br />
the leading position in the extrusion<br />
industry.<br />
Author<br />
Shi Lili works as a freelance journalist for<br />
foreign media and is a consultant for foreign<br />
companies interested in Beijing, P.R.<br />
of China. Amongst others, she has two<br />
years of working experience in the Foreign<br />
Affairs Department of China Nonferrous<br />
Metals Industry Association (CNIA).<br />
76 ALUMINIUM · 1-2/2008
The European <strong>Alu</strong>minium in Renovation<br />
Award, which ran throughout 2007, involved<br />
15 European countries, a series of national<br />
competitions and a European final rewarding<br />
the most innovative and sustainable uses<br />
of aluminium in building renovation. The<br />
winning entries illustrate that whether used<br />
to preserve a piece of national heritage or<br />
to upgra<strong>de</strong> the environmental performance<br />
of resi<strong>de</strong>ntial or utility buildings, aluminium<br />
is the most sustainable solution.<br />
The 2007 Renovation Award is an initiative<br />
of the ‘Building Group’ of the European<br />
<strong>Alu</strong>minium Association (EAA) and the <strong>Alu</strong>minium<br />
For Future Generations programme<br />
in cooperation with national aluminium<br />
associations in many European countries. An<br />
international jury judged 47 entries nomi-<br />
ALUMINIUM · 1-2/2008<br />
nated by seven national competitions. Five<br />
Awards, three Special Prizes, a Jury Prize<br />
and one Honourable Mention were given<br />
to representatives of the winning projects.<br />
Presentation of the awards and other prize<br />
winners took place during the Batimat 2007<br />
at the Expo Center Porte <strong>de</strong> Versailles in<br />
Paris. Batimat is Europe’s biggest Expo for<br />
MARKETS AND TECHNOLOGY<br />
Winners of the<br />
European <strong>Alu</strong>miniumin Renovation Award 2007<br />
Project: The restoration and recovery of the Pirelli building<br />
was conducted via a system of interventions which<br />
provi<strong>de</strong>d the <strong>de</strong>tails of the entire operational process in<br />
or<strong>de</strong>r to verify the formal, performance and technical<br />
material qualities, time and costs for execution.<br />
Before restoration there was the existing aluminium<br />
curtain wall in a stick system with a total surface of approx.<br />
10,800 sqm. The curtain wall is based on a stick<br />
system in anodised aluminium in modules 2850 mm<br />
in width and 1854 mm in height, completely glazed in<br />
opening parts measuring 1900 mm with a chamber and<br />
fixed parts measuring 950 mm. In addition, two bands of<br />
skylights, above and below, constructed in opaque panels<br />
like sandwiches formed with an exterior pane of glass and<br />
an internal sheet in galvanised steel, all linked around the<br />
perimeter by a rubber gasket and weather strip.<br />
Jury judgement: The Pirelli skyscraper is a symbol of mo<strong>de</strong>rn<br />
architecture created by the famous Gio Ponti in the<br />
fifties. The building was partly damaged by an aeroplane<br />
acci<strong>de</strong>nt. There has been a <strong>special</strong> <strong>de</strong>bate in Italy on the<br />
methodology for restoration and conservation. The Region<br />
of Lombardy <strong>de</strong>ci<strong>de</strong>d to proceed using ‘anastylosis’,<br />
a reconstruction technique based on careful study and<br />
Building and Architecture.<br />
The concept of aluminium in renovation<br />
covered not only renovation, but also<br />
restoration and re-construction provi<strong>de</strong>d the<br />
former structure of the building had been<br />
maintained such as changing the function<br />
of an existing building, e. g. turning a warehouse<br />
into apartments.<br />
The following criteria were taken into<br />
account when assessing the entries:<br />
• Significant use of <strong>Alu</strong>minium<br />
• Contemporary <strong>de</strong>sign<br />
• Life cycle thinking<br />
• Energy efficiency<br />
• Socio-economic impact<br />
• Ad<strong>de</strong>d value to the original building<br />
In the following a presentation of some of<br />
the award-winning projects.<br />
Award in the Category Historical Buildings<br />
Pirelli Building Milan, Italy<br />
Architects: Renato Sarno Group and Corvino+Multari <strong>Alu</strong>minium products: Metra<br />
mensuration using original architectural elements where<br />
possible. This building is the first example of applying<br />
this conservation technique to curtain walling.<br />
Furthermore, new performance standards ma<strong>de</strong> it<br />
necessary to test new possibilities in the use of aluminium.<br />
They succee<strong>de</strong>d in restoring the aluminium where<br />
it could be recovered (disassembly, cleaning, re-anodising<br />
and re-assembly of the elements). For parts which<br />
were <strong>de</strong>stroyed new ones had to be ma<strong>de</strong> with the same<br />
morphology. This project truly restored as much of the<br />
original material as possible as well as meeting the highest<br />
of mo<strong>de</strong>rn building standards.<br />
�<br />
<strong>Alu</strong>minium Award Winner Country Special Prize Winner Country<br />
Private Houses Maison à Fleury-les-Aubrais France Cladding & Roofing BMW-Hochhaus, München Germany<br />
Collective Housing Warehouse Nautilus, Scheveningen Netherlands Doors & Windows Borgo Wührer Village, Brescia Italy<br />
Utility Buildings Café Mayer, Vöcklabruck Austria Curtain Walls Plaza 14 Business Centre, Zaragoza Spain<br />
Public Buildings Rich Mix Bethnall Green, London UK Jury Prize San Ponziano Library, Lucca Italy<br />
Historical Buildings Pirelli Skyscraper, Milano Italy Honourable Mention Casino Kursaal Oosten<strong>de</strong> Belgium<br />
The prize winners of the European <strong>Alu</strong>minium in Renovation Award 2007<br />
Photos: EAA<br />
77
MARKETS AND TECHNOLOGY<br />
Award in the Category Public Buildings<br />
Rich Mix Bethnall Green London, England<br />
Architect: Penoyre & Prasad <strong>Alu</strong>minium products: Kalzip<br />
Project: An East End of London property that has been<br />
transformed by the use of external aluminium louvres<br />
whilst still maintaining its original faca<strong>de</strong>. Not only has<br />
the property been totally transformed but also the internal<br />
space has been given a new lease of life by controlling<br />
solar gain.<br />
Jury judgement: The minimal intervention of the existing<br />
building by the use of coloured aluminium louvres<br />
has created a completely new and mo<strong>de</strong>rn view of this<br />
complex. It is not only an architectural feature but also a<br />
way to control the solar heat. Together with the chosen<br />
colours the faca<strong>de</strong> gives a vivid and variable impression.<br />
Special Prize for Cladding and Roofing<br />
BMW Hochhaus Munich, Germany<br />
Architect: eS 21 engineering & structure <strong>Alu</strong>minium products: Otto Valenta<br />
Project: <strong>Alu</strong>minium cladding of the pre-stressed concrete<br />
king pins. One has to be able to open up any such cladding<br />
so that the pre-stressed concrete construction can<br />
be inspected in future. In addition, because there were<br />
only a few points suitable for attaching the large-format<br />
cladding components, the components had to have a low<br />
structural weight while at the same time the structure had<br />
to have a high stiffness. Because of the <strong>special</strong> geometry, it<br />
was necessary to manufacture curved aluminium ribbed<br />
shells with a bi-directional curvature. One has to imagine<br />
a 3D free-form shape such as in car body manufacturing<br />
but significantly larger. Other challenges were the erection<br />
at a height of 100 metres un<strong>de</strong>r difficult conditions,<br />
the high <strong>de</strong>gree of precision and the automation of the<br />
manufacturing using welding <strong>de</strong>vices.<br />
Special Prize for Doors & Windows<br />
Borgo Wührer Village Brescia, Italy<br />
Architect: Studio Racheli Architetti <strong>Alu</strong>minium Products: Metra<br />
Project: Recovering the area of the former Whürer factory,<br />
even the substitution of the windows required particular<br />
attention. The original elements, ma<strong>de</strong> of iron and glass,<br />
were substituted with a personalised version of an existing<br />
aluminium frame system. The use of aluminium gives<br />
remarkable advantages in the maintenance, non-<strong>de</strong>formability<br />
as well as in thermal and acoustic insulation. The<br />
substitution of the windows improved the thermal and<br />
energy-saving performances in the different spaces of the<br />
historical factory. On the other hand, it allowed the keeping<br />
of the continuity of language present in the images of<br />
the industrial complex, which was built in the 1880’s.<br />
Jury judgement: The intervention is <strong>de</strong>dicated to the restoration<br />
of an existing industrial complex now converted<br />
into mixed commercial use. The <strong>de</strong>sign respected the existing<br />
arrangement of windows also tackling the new re-<br />
Jury judgement: This refurbishment shows an innovative<br />
way to use aluminium. It is intelligent cladding, completely<br />
prefabricated and put into position in short time.<br />
quirements dictated by new energy standards. All of this<br />
is done in relation to the significant variety of the existing<br />
window frames. This required research of new profiles in<br />
respect of the 19th century industrial structures. �<br />
78 ALUMINIUM · 1-2/2008
Frie<strong>de</strong>nsnobelpreis für IPCC<br />
Ein Quäntchen Ehre auch für Halvor Kvan<strong>de</strong><br />
Halvor Kvan<strong>de</strong>, <strong>de</strong>r im Bereich<br />
Primary Production bei Hydro<br />
arbeitet, forscht seit vielen Jahren,<br />
um das Elektrolyseverfahren für<br />
<strong>Alu</strong>minium zu verbessern. Seine<br />
Forschungsarbeiten zielen unter<br />
an<strong>de</strong>rem darauf, die Emissionen<br />
von CO 2 und perfluorierter Kohlenwasserstoffe<br />
(PFC) zu reduzieren.<br />
Diese Arbeit war Teil eines<br />
<strong>de</strong>r letzten Berichte <strong>de</strong>s U. N.<br />
Klimapanels IPCC, das zusammen<br />
mit <strong>de</strong>m ehemaligen US-Vizepräsi<strong>de</strong>nten<br />
Al Gore <strong>de</strong>n diesjährigen<br />
Frie<strong>de</strong>nsnobelpreis erhielt.<br />
Kvan<strong>de</strong>, <strong>de</strong>r in Oslo arbeitet, ist einer<br />
von zahlreichen Forschern aus über<br />
130 Län<strong>de</strong>rn, die ihren Beitrag zu<br />
<strong>de</strong>n letzten IPCC-Berichten geleistet<br />
haben. Er ist überzeugt, dass dieser<br />
Preis das öffentliche Bewusstsein verän<strong>de</strong>rn<br />
wird, und fügt hinzu: „Er �<br />
• accessible at least a week before<br />
the printed edition<br />
• available from any location<br />
• simple download<br />
• keyword researches<br />
• linked list of contents<br />
• direct contact with advertisers<br />
ALUMINIUM · 1-2/2008<br />
Nobel Peace Prize for IPCC<br />
A small slice of the glory also for Halvor Kvan<strong>de</strong><br />
Halvor Kvan<strong>de</strong>, who works in the<br />
Primary Production sector of Hydro,<br />
has been working for many<br />
years to improve the aluminium<br />
electrolysis process. Part of his<br />
work inclu<strong>de</strong>s trying to reduce<br />
CO 2 and perfluorocarbon (PFC)<br />
gas emissions to the atmosphere,<br />
and has been inclu<strong>de</strong>d in one of<br />
the recent reports from the Intergovernmental<br />
Panel on Climate<br />
Change (IPCC), which was co-winner<br />
of the Nobel Peace Prize for<br />
2007, along with former U. S. Vice<br />
Presi<strong>de</strong>nt Al Gore.<br />
Kvan<strong>de</strong>, who is based in Oslo, is<br />
among the many researchers from<br />
more than 130 nations who have con-<br />
www<br />
aluminiumePaper.com<br />
Please be our guest<br />
and discover the benefi ts of the<br />
ALUMINIUM-ePaper yourself in a<br />
free three-month trial:<br />
ENVIRONMENT AND ECOLOGY<br />
tributed to the writing of these recent<br />
IPCC reports. “I strongly believe this<br />
prize will make a difference,” he says.<br />
“And it can also be seen in light of the<br />
ongoing <strong>de</strong>bate and the need for political<br />
lea<strong>de</strong>rship. Some activists and<br />
scientists link next year’s presi<strong>de</strong>ntial<br />
election in the US to the <strong>de</strong>stiny of<br />
global environment”.<br />
Better control of the<br />
production process<br />
PFC gases are not ma<strong>de</strong> naturally,<br />
Kvan<strong>de</strong> points out, and their major<br />
source is primary aluminium production.<br />
They contribute to global<br />
warming, as they prevent the infrared<br />
heat loss from the earth passing �<br />
79
UMWELT UND ÖKOLOGIE<br />
kann auch im Licht <strong>de</strong>r gegenwärtigen<br />
Debatte und <strong>de</strong>s Bedarfs für politische<br />
Entscheidungen gesehen wer<strong>de</strong>n. Einige<br />
Aktivisten und Wissenschaftler<br />
verbin<strong>de</strong>n die Präsi<strong>de</strong>ntenwahl 2008<br />
in <strong>de</strong>n USA mit <strong>de</strong>r Entwicklung <strong>de</strong>r<br />
globalen Umwelt“.<br />
Bessere Kontrolle <strong>de</strong>s<br />
Produktionsprozesses<br />
Perfluorierte Kohlenwasserstoffe entstän<strong>de</strong>n<br />
nicht natürlich, unterstreicht<br />
Kvan<strong>de</strong>, die Hauptquelle für diese<br />
Gase sei die Primäraluminiumherstellung.<br />
Sie tragen zur globalen Er<strong>de</strong>rwärmung<br />
bei, da sie verhin<strong>de</strong>rn,<br />
dass die Erdwärme in die Atmosphäre<br />
abgegeben wird.<br />
Die Produktion von einem Kilogramm<br />
<strong>Alu</strong>minium hat gegenwärtig<br />
eine Emission von etwa vier Kilogramm<br />
CO 2 zur Folge. Viele <strong>Alu</strong>miniumhersteller<br />
in <strong>de</strong>r Welt verursachten<br />
noch höhere Emissionswerte, sagt<br />
Kvan<strong>de</strong>. „Vor 15 bis 20 Jahren war<br />
man allgemein <strong>de</strong>r Auffassung, dass<br />
die Ano<strong>de</strong>neffekte in <strong>de</strong>n Elektrolysezellen<br />
notwendig waren, damit diese<br />
gut funktionierten. Heute wissen wir,<br />
dass dies eher ein Zeichen für <strong>de</strong>n<br />
schlechten Betrieb <strong>de</strong>r Zellen ist. Die<br />
gesamte Branche ist sich darüber im<br />
Klaren und Ano<strong>de</strong>neffekte wer<strong>de</strong>n<br />
nun als Abweichung betrachtet, die<br />
durch präziseres und kontrolliertes<br />
Befüllen mit <strong>Alu</strong>miniumoxid vermie<strong>de</strong>n<br />
wer<strong>de</strong>n können“, erklärt er.<br />
Durch eine bessere Kontrolle <strong>de</strong>s Produktionsprozesses<br />
sind diese Emissionen<br />
mittlerweile beträchtlich reduziert<br />
wor<strong>de</strong>n. In Norwegen sei es <strong>de</strong>r<br />
<strong>Alu</strong>miniumindustrie gelungen, <strong>de</strong>n<br />
Ausstoß von Treibhausgasen im Zeitraum<br />
1990 bis 2005 um mehr als 55<br />
Prozent zu verringern, so Kvan<strong>de</strong>.<br />
Dilemma<br />
„Wir müssen uns jedoch das Dilemma<br />
eingestehen“, meint er und verweist<br />
darauf, dass die steigen<strong>de</strong> Nachfrage<br />
nach <strong>Alu</strong>minium zu noch höheren<br />
CO 2-Emissionen führen kann, auch<br />
wenn diese pro produzierter Einheit<br />
zurückgehen.<br />
In <strong>de</strong>n vergangenen Jahren hat<br />
die weltweite <strong>Alu</strong>miniumindustrie<br />
ihre Produktionsmenge beträchtlich<br />
gesteigert – um ganze 31 Prozent<br />
in <strong>de</strong>n Jahren 2000 bis 2005. Die<br />
Treibhausemissionen konnten im<br />
gleichen Zeitraum um sechs Prozent<br />
verringert wer<strong>de</strong>n. Darin enthalten<br />
Halvor Kvan<strong>de</strong> hat dazu beigetragen, das<br />
Elektrolyseverfahren für <strong>Alu</strong>minium zu<br />
verbessern<br />
Hydro researcher Halvor Kvan<strong>de</strong> has been<br />
working for many years to improve the<br />
aluminium electrolysis process<br />
sind die Emissionen aus <strong>de</strong>r Bauxitgewinnung,<br />
<strong>de</strong>r Herstellung von Toner<strong>de</strong>,<br />
<strong>de</strong>r Ano<strong>de</strong>nproduktion sowie<br />
aus <strong>de</strong>m Schmelzen und Gießen von<br />
<strong>Alu</strong>minium.<br />
Laut <strong>de</strong>m Londoner International<br />
<strong>Alu</strong>minium Institute (IAI) ist die Reduktion<br />
um sechs Prozent die Folge<br />
einer 56-prozentigen Reduktion<br />
<strong>de</strong>r Emissionen von perfluorierten<br />
Kohlenwasserstoffen und einer 12prozentigen<br />
Reduktion an<strong>de</strong>rer<br />
Emissionen pro Tonne produziertes<br />
Primäraluminium. „Für uns heißt die<br />
Herausfor<strong>de</strong>rung, diesen Trend weiterzuführen“,<br />
so Kvan<strong>de</strong>.<br />
through the atmosphere.<br />
Production of one kilogram of aluminium<br />
now causes about four kilograms<br />
of CO 2 emissions. Many aluminium<br />
producers around the world<br />
produce even higher emissions than<br />
this, Kvan<strong>de</strong> comments. “About 15<br />
to 20 years ago it was generally believed<br />
that the ano<strong>de</strong> effects in the<br />
electrolytic cells were necessary for<br />
good cell operation. Today we may<br />
consi<strong>de</strong>r them to be a sign of poorly<br />
operated cells. The entire industry is<br />
now aware of this, and ano<strong>de</strong> effects<br />
are now consi<strong>de</strong>red as a <strong>de</strong>viation,<br />
which can be prevented by more precise<br />
and controlled feeding of aluminium<br />
oxi<strong>de</strong>”, he says.<br />
Through better control of the production<br />
process, these emissions have<br />
actually been consi<strong>de</strong>rably reduced. In<br />
Norway, the aluminium industry has<br />
been able to reduce its specific greenhouse<br />
gas emissions by more than 55<br />
percent over the period 1990-2005.<br />
Dilemmas<br />
“We have to be honest about the dilemmas,”<br />
Kvan<strong>de</strong> says, referring to<br />
how increasing <strong>de</strong>mand for materials<br />
can lead to even higher CO2 emissions,<br />
<strong>de</strong>spite lower emissions per<br />
produced unit.<br />
In recent years, the world’s aluminium<br />
industry has increased its total<br />
output consi<strong>de</strong>rably – as much as 31<br />
percent from 2000 to 2005, while its<br />
total greenhouse gas emissions were<br />
reduced by six percent over that period.<br />
This inclu<strong>de</strong>s emissions for bauxite<br />
mining, alumina refining, ano<strong>de</strong><br />
production, aluminium smelting and<br />
casting.<br />
According to the International<br />
<strong>Alu</strong>minium Institute (IAI), the six percent<br />
reduction is the result of 56 percent<br />
reduction in PFC emissions and<br />
12 percent in other direct emissions<br />
per tonne of primary aluminium produced.<br />
“Our challenge is to continue<br />
� this trend,” Kvan<strong>de</strong> says. �<br />
60.000 Literaturangaben zum Thema <strong>Alu</strong>minium<br />
Kontakt: karsten.hein@aluinfo.<strong>de</strong><br />
80 ALUMINIUM · 1-2/2008<br />
Foto: Kåre Foss
OFFICIAL MEDIA PARTNER<br />
Important information for<br />
all exhibitors at<br />
ALUMINIUM 2008<br />
in Essen<br />
<strong>Alu</strong>minium Praxis and APT <strong>Alu</strong>minium News have been jointly<br />
nominated the exclusive offi cial newspapers for German<br />
and English speaking participants respectively,<br />
at ALUMINIUM 2008 in Essen.<br />
Actual schedule:<br />
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OFFICIAL OFFICIA OFFICIA AL MEDIA MEDIA PARTNER PARTNER<br />
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<strong>Alu</strong>minium Praxis, has been for many years the offi cial media partner and since 2006 the offi cial Fair Newspaper. p p<br />
It will publish again the Fair Newspaper for the German speaking audience in September together with<br />
of the forthcoming g ALUMINIUM 2008 in Essen. Due to popular <strong>de</strong>mand, APT <strong>Alu</strong>minium News together<br />
with<br />
will publish a Fair Newspaper edition for the English speaking participants and visitors from<br />
all over the world for the fi rst time.<br />
So every participating exhibitor, will benefi t from:<br />
• Print run of 20,000 copies – instead of 8,000 –<br />
• Direct distribution to all visitors from 2006<br />
• Direct distribution to exhibitors in 2008, ahead of the Fair dates<br />
• Distribution to hotels in Essen hosting guests as<br />
offi cial Fair resi<strong>de</strong>nce<br />
• Distribution to visitors at the entrance as well as insi<strong>de</strong><br />
the Fair grounds by our <strong>de</strong>signated hostesses<br />
• Display on the Technical Press stand<br />
• Special reference from the organisers<br />
Company<br />
With your client target group un<strong>de</strong>r one roof at ALUMINIUM 2008, your<br />
advertisement with our Fair Newspapers will be reaching effectively<br />
Last and First Name<br />
every present and visiting potential customer to your business!<br />
As you may appreciate, we are constantly working in improving our<br />
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Special rates for series advertising with our ALUMINIUM all over<br />
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offer our insight to your specifi c marketing requirements for a most<br />
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event.<br />
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To take best advantage of potential benefi ts, you may fi ll in and send<br />
to us the enclosed form or alternatively call<br />
Remarks<br />
Stefan Schwichtenberg on: +49-511/7304-142<br />
or your area agent.<br />
Sincerely,<br />
Your ALUMINIUM 2008 Fair Newspaper Team<br />
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ALUMINIUM<br />
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BDI-Studie zum Klimaschutz<br />
CO 2 -Reduzierungspotenzial in NE-Branche nur<br />
zu Lasten <strong>de</strong>r Wettbewerbsfähigkeit möglich<br />
Vor <strong>de</strong>m Hintergrund <strong>de</strong>r Klimapolitik<br />
<strong>de</strong>r Bun<strong>de</strong>sregierung hat<br />
<strong>de</strong>r Bun<strong>de</strong>sverband <strong>de</strong>r Deutschen<br />
Industrie (BDI) e. V. McKinsey<br />
& Company beauftragt, Kosten<br />
und Potenziale zur Reduzierung<br />
von Treibhausgasemissionen zu<br />
untersuchen. An <strong>de</strong>r Erarbeitung<br />
<strong>de</strong>r gleich lauten<strong>de</strong>n Studie haben<br />
mehr als 70 Unternehmen und<br />
Verbän<strong>de</strong> in Deutschland mitgewirkt.<br />
Die Studie i<strong>de</strong>ntifiziert<br />
technologische Ansätze zur Vermeidung<br />
von Treibhausgasen und<br />
<strong>de</strong>ren Kosten aus Entschei<strong>de</strong>rsicht<br />
in <strong>de</strong>n Sektoren Energie, Industrie,<br />
Gebäu<strong>de</strong>, Abfall- sowie Landwirtschaft<br />
und Transport.<br />
Die WVM Wirtschaftsvereinigung<br />
Metalle e. V. hat innerhalb <strong>de</strong>s Sektors<br />
Industrie in einer speziellen Arbeitsgruppe<br />
„NE-Metalle“ gemeinsam mit<br />
Mitgliedsunternehmen und McKinsey<br />
Vermeidungshebel und die damit<br />
verbun<strong>de</strong>nen Kosten für die gesamte<br />
NE-Metallbranche i<strong>de</strong>ntifiziert und<br />
bewertet. Ergebnis <strong>de</strong>r Arbeitsgruppe:<br />
Bis 2020 können durch Effizienzverbesserung<br />
bei <strong>de</strong>r Wärmebehandlung<br />
und gradueller Optimierung in<br />
<strong>de</strong>r Elektrolyse etwa 1,3 Mio. Tonnen<br />
CO 2-Äquivalente gegenüber 2004 reduziert<br />
wer<strong>de</strong>n. Bis zum Jahr 2030<br />
sei sogar eine Reduktion um 1,6 Mio.<br />
Tonnen möglich. Davon entfallen<br />
rund 1 Mio. Tonnen auf die Wärmebehandlung<br />
und 0,5 Mio. Tonnen auf<br />
die Elektrolyse. Effizienzverbesserungen<br />
durch <strong>de</strong>n Einsatz energiesparen<strong>de</strong>r<br />
Querschnittstechnologien wie<br />
lastgeregelte elektrische Antriebe und<br />
Motorsysteme sowie Raumheizung<br />
und -beleuchtung spielen nur eine<br />
untergeordnete Rolle.<br />
Bei steigen<strong>de</strong>r Produktion kann<br />
durch die Maßnahmen das Emissionsniveau<br />
von 15 Mio. Tonnen CO 2-<br />
Äquivalente bis 2030 in etwa konstant<br />
gehalten wer<strong>de</strong>n. Die Maßnahmen<br />
beruhen auf <strong>de</strong>r Abschätzung, welche<br />
Durchdringungsrate heute bekannte<br />
Energieeffizienztechnik 2020<br />
ALUMINIUM · 1-2/2008<br />
bzw. 2030 haben wird. Bei <strong>de</strong>r Wärmebehandlung<br />
ist eine vollständige<br />
Durchdringung bei Schmelz- und<br />
Homogenisierungsöfen bereits 2020<br />
wahrscheinlich. Insgesamt können<br />
damit rund 15 Prozent <strong>de</strong>s für diese<br />
Produktionsprozesse heute benötigten<br />
Energiebedarfs eingespart wer<strong>de</strong>n.<br />
In <strong>de</strong>r Elektrolyse ist erst 2030<br />
mit einer vollständigen Umsetzung<br />
<strong>de</strong>r Maßnahmen zu rechnen, wodurch<br />
etwa fünf Prozent <strong>de</strong>s heutigen<br />
Stromverbrauchs eingespart wer<strong>de</strong>n<br />
können.<br />
Allerdings entstehen bis 2020 für<br />
Maßnahmen bei <strong>de</strong>r Wärmebehandlung<br />
und Elektrolyse Vermeidungskosten<br />
von mehr als 20 bzw. 50 Euro<br />
je Tonne CO 2, so dass die Maßnah-<br />
„Bis 2020 können durch Effizienzverbesserung<br />
bei <strong>de</strong>r Wärmebehandlung und<br />
gradueller Optimierung in <strong>de</strong>r Elektrolyse<br />
etwa 1,3 Mio. Tonnen CO 2 -Äquivalente gegenüber<br />
2004 reduziert wer<strong>de</strong>n“<br />
men aus Entschei<strong>de</strong>rsicht unwirtschaftlich<br />
sind und die internationale<br />
Wettbewerbsfähigkeit beeinträchtigen<br />
wür<strong>de</strong>n. Auf <strong>de</strong>n längeren Zeitraum<br />
bis 2030 berechnet fallen nur<br />
die Kosten für Maßnahmen in <strong>de</strong>r<br />
Wärmebehandlung auf unter 20 Euro<br />
je Tonne CO 2. Noch mehr als diese<br />
direkten Kosten wird die internationale<br />
Wettbewerbsfähigkeit <strong>de</strong>r<br />
NE-Metallindustrie durch steigen<strong>de</strong><br />
UMWELT UND ÖKOLOGIE<br />
Strompreise gefähr<strong>de</strong>t. Denn allein<br />
solche Maßnahmen in <strong>de</strong>r Energiewirtschaft,<br />
die für einen Preis von bis<br />
zu 20 Euro je Tonne CO 2 verwirklicht<br />
wer<strong>de</strong>n, erhöhen <strong>de</strong>n Strompreis um<br />
Anzeige<br />
www.inotherm-gmbh.<strong>de</strong><br />
weitere acht Euro je Megawattstun<strong>de</strong>.<br />
Die WVM betont daher, dass bei <strong>de</strong>n<br />
Maßnahmen beson<strong>de</strong>res Augenmerk<br />
auf die Erhaltung <strong>de</strong>r Wettbewerbsfähigkeit<br />
<strong>de</strong>utscher Unternehmen,<br />
vor allem bei energieintensiven Industrien,<br />
gelegt wer<strong>de</strong>n muss. Die<br />
Produktion am Standort Deutschland<br />
kann nur gesichert wer<strong>de</strong>n, wenn die<br />
Kosteneffizienz das entschei<strong>de</strong>n<strong>de</strong><br />
Kriterium für die Auswahl und <strong>de</strong>n<br />
Zuschnitt <strong>de</strong>r Klimaschutzmaßnahmen<br />
ist. Hier sind nicht zuletzt sektorübergreifen<strong>de</strong><br />
Rückwirkungen zu beachten,<br />
z. B. steigen<strong>de</strong> Strompreise.<br />
Die Akzeptanz <strong>de</strong>r Klimaschutzpolitik<br />
wird davon abhängen, welche<br />
Belastungen <strong>de</strong>r Verbraucher zu tragen<br />
hat. Hierzu bietet die BDI-Studie<br />
vielfältige Ansatzpunkte. Politisch<br />
kommt es bei <strong>de</strong>r Umsetzung <strong>de</strong>r<br />
europäischen und <strong>de</strong>utschen Klima-<br />
und Energiebeschlüsse vom Frühjahr<br />
bzw. Sommer 2007 darauf an, die<br />
Min<strong>de</strong>rungslasten fairer als bisher zu<br />
verteilen und am Kriterium <strong>de</strong>r Kosteneffizienz<br />
auszurichten. So sollten<br />
erneuerbare Energien dort ausgebaut<br />
wer<strong>de</strong>n, wo die Potenziale noch weitgehend<br />
unausgeschöpft sind und <strong>de</strong>r<br />
Ausbau mit beson<strong>de</strong>rs geringen Kosten<br />
verbun<strong>de</strong>n ist. Vor diesem Hintergrund<br />
liefert die vorgelegte Studie im<br />
Sinne einer „Preisliste“ (Kosten aus<br />
Entschei<strong>de</strong>rsicht) hierfür fundierte<br />
Orientierungshilfen.<br />
WVM-Kontakt:<br />
Tel: +49 (0)30 726 207 198<br />
info@wvmetalle.<strong>de</strong><br />
82
Photo: Rio Tinto Alcan<br />
<strong>Alu</strong>minium smelting industry<br />
MMC, Chalco and Binladin<br />
firm up Saudi smelter plan<br />
MMC Corp., <strong>Alu</strong>minium Corp. of China<br />
(Chalco) and Saudi Binladin Group<br />
(SBG) have firmed up plans to build<br />
ALUMINIUM · 1-2/2008<br />
a 1m tpy aluminium smelter in Saudi<br />
Arabia. The three companies signed<br />
an agreement to build the US$3bn<br />
smelter in Jazan Economic City (JEC).<br />
The companies will form joint venture<br />
company Sino-Saudi Jazan <strong>Alu</strong>-<br />
UC Rusal completes five-year casthouse revamp<br />
In November UC Rusal completed its<br />
casthouse mo<strong>de</strong>rnisation programme<br />
at four smelters, increasing the share of<br />
value-ad<strong>de</strong>d products to 50% of total<br />
production volume. The projects began<br />
in 2002 and cost about US$130m. This<br />
was aimed at increasing the diversity of<br />
casthouse products, which now inclu<strong>de</strong><br />
rolling slabs, extrusion billets, silicon alloys<br />
for automotive uses, highly pure alloys<br />
for the electrical engineering industry<br />
and rolled wire. The four smelters<br />
involved are: Sayanogorsk, Krasnoyarsk,<br />
Bratsk and Novokuznetsk. The mo<strong>de</strong>rnisation<br />
programme enables them to<br />
produce more than 250 new alloys, to<br />
enter new markets and to significantly<br />
increase their customer base.<br />
Feasibility study on<br />
metals complex in Kyrgyzstan<br />
After its failure to accomplish a similar<br />
project in neighbouring Tajikistan, UC<br />
Rusal has resumed exploring opportunities<br />
for building an energy and metals<br />
complex in Kyrgyzstan. In Kyrgyzstan,<br />
which has vast hydropower potential,<br />
Rusal hopes to create an industrial cluster<br />
comprising electricity and aluminium<br />
production facilities. With a new feasi-<br />
bility study, Rusal is effectively revisiting<br />
a plan dating back to 2004 when the<br />
then Kyrgyzstan presi<strong>de</strong>nt gave the<br />
green light for the construction of an<br />
aluminium smelter and electricity plants.<br />
That scheme had envisaged building<br />
two hydroelectric power stations (Kambarata<br />
1 and 2) on the Naryn river and<br />
using locally available nepheline instead<br />
of bauxite ore as raw material for aluminium<br />
production. Project costs were<br />
roughly estimated at US$2bn.<br />
Point fee<strong>de</strong>r<br />
installation at KrAZ completed<br />
In November, UC Rusal’s Krasnoyarsk<br />
<strong>Alu</strong>minium Smelter completed the<br />
installation of automatic alumina pointfee<strong>de</strong>rs.<br />
KrAZ is the first aluminium<br />
smelter in Russia based on slotted ano<strong>de</strong><br />
technology equipped with automatic<br />
point fee<strong>de</strong>rs. The project started in<br />
2004 and cost over US$38m as part of<br />
the strategic programme of ecological<br />
mo<strong>de</strong>rnization of KrAZ. Today, all its<br />
1954 electrolytic cells based on So<strong>de</strong>rberg<br />
technology are equipped with automatic<br />
alumina point fee<strong>de</strong>rs which has<br />
reduced fluori<strong>de</strong> emissions by 10%, tarry<br />
substances by 3% and dust by 30%.<br />
COMPANY NEWS WORLDWIDE<br />
minium Ltd to un<strong>de</strong>rtake the project,<br />
with Chalco and a Saudi consortium,<br />
including SBG, each taking a 40%<br />
stake in the new company. MMC will<br />
hold the remaining 20%. The group<br />
also intends to build a 1,860 MW<br />
power plant at US$2bn to power the<br />
smelter. The shares held by MMC, by<br />
the Saudi consortium including SBG<br />
and by Chalco will be in proportions<br />
of 50:30:20 percent. Construction of<br />
the smelter and power plant is scheduled<br />
to begin during the second half<br />
of 2008 and be completed in 2012.<br />
Chalco and its affiliate China <strong>Alu</strong>minium<br />
International Engineering<br />
Co. will provi<strong>de</strong> alumina technology<br />
for the smelter.<br />
Indian aluminium industry to receive<br />
huge investment by 2012<br />
In November Indian aluminium industry<br />
announced it expected to invest<br />
Rs1,000bn (US$25bn) over the<br />
next five years. Installed capacity will<br />
go up from the existing 1.1m tpy to<br />
4m tpy. Consumption of aluminium<br />
in India is growing at 18% per year<br />
compared with the global 4.4%. By<br />
2015, Indian aluminium use will grow<br />
to 2.75m tpy.<br />
CVRD gets new name<br />
The Brazilian Companhia Vale do Rio<br />
Doce (CVRD) has launched a change<br />
to its short name. Previously known<br />
by its initials, CVRD, the miner will<br />
now go by Vale.<br />
New Indian smelter<br />
expected online by end of March<br />
Vedanta’s new 500,000 tpy smelter in<br />
the eastern Indian state of Orissa is<br />
expected to produce its first aluminium<br />
by the end of March 2008. The<br />
first 250,000 tpy stage of the smelter<br />
should be mechanically complete in<br />
February, with the first production in<br />
the following month. The smelter will<br />
be fed with alumina from a new 1.4m<br />
tpy refinery, also in Orissa. The alumina<br />
refinery has started production,<br />
although Vedanta has encoun- �<br />
83
COMPANY NEWS WORLDWIDE<br />
tered problems getting government<br />
approval for mining bauxite in the<br />
Niyamgiri hills.<br />
Dubal-Mubadala joint venture<br />
to build smelter in Algeria<br />
A pre-feasibility study on a major aluminium<br />
smelter in Algeria initiated by<br />
Emirates <strong>Alu</strong>minium is progressing<br />
well, as the company has showcased<br />
the proposed mo<strong>de</strong>l of the project.<br />
The smelter will be built in partnership<br />
with Algerian state-owned oil<br />
and gas company Sonatrach in the<br />
new industrial and port zone of Béni-<br />
Saf in north-western Algeria. The proposed<br />
smelter will have an initial capacity<br />
of 700,000 tpy with the option<br />
of doubling to 1.4m tpy in time. The<br />
smelter comprises two potlines, an<br />
ano<strong>de</strong> carbon plant, a casthouse, a sea<br />
port for major raw material imports<br />
and finished product export, bulk<br />
raw material unloading, storage and<br />
handling facilities, a storage yard for<br />
finished aluminium products, a power<br />
plant of 2,000 MW (combined cycle,<br />
gas-fired) linked to a water <strong>de</strong>salination<br />
plant and auxiliary infrastructure.<br />
The Béni-Saf aluminium smelter will<br />
be built using highly-efficient, environment-friendly<br />
technologies, and<br />
the smelter will use Dubal’s advanced<br />
DX reduction cell technology. The<br />
production of primary aluminum has<br />
the potential to initiate a downstream<br />
transformation industry with the capacity<br />
for many small- and medium<br />
sized businesses in Algeria to evolve<br />
into sustainable operations.<br />
Gulf investment company<br />
eyes greenfield project in India<br />
Ras-Al-Khaima Investment Authority<br />
(Rakia), a provincial investment company<br />
of the United Arab Emirates, is<br />
planning to invest US$2bn in a Greenfield<br />
integrated aluminium complex in<br />
the India state of Andhra Pra<strong>de</strong>sh. Rakia<br />
has signed an agreement with the<br />
Andhra Pra<strong>de</strong>sh Mineral Development<br />
Authority for bauxite reserves to feed a<br />
planned facility in Visakhapatnam. Rakia<br />
is consi<strong>de</strong>ring a 1.5m tpy alumina<br />
refinery and a 350,000 tpy smelter.<br />
ENRC opens Kazakh smelter<br />
Eurasian Natural Resources Corp.<br />
(ENRC) has inaugurated its aluminium<br />
smelter in Pavlodar, Kazakhstan,<br />
with initial capacity of 62,500 tpy,<br />
planned to increase to 125,000 tpy<br />
in 2008 and 250,000 tpy by 2011.<br />
The project was completed ahead of<br />
schedule. The smelter comprises two<br />
potlines, a casthouse and ano<strong>de</strong> production.<br />
Power is supplied through a<br />
sub-division of ENRC’s energy division.<br />
Nalco moves ahead with<br />
big Indonesian smelter project<br />
India’s state-owned National <strong>Alu</strong>minium<br />
Corporation (Nalco) agreed<br />
to invest US$3bn in a 500,000 tpy<br />
aluminium smelter in the Indonesian<br />
province of Sumatra. After signing an<br />
MoU due in January, Nalco will conduct<br />
a feasibility study on the project.<br />
Nalco will build a 250,000 tpy smelter<br />
in the initial phase and ramp up to<br />
the full 500,000 tpy later. The exact<br />
timeline for the plant has not been<br />
released. <strong>Alu</strong>mina and other raw materials<br />
nee<strong>de</strong>d for the smelter will be<br />
shipped from India. The project inclu<strong>de</strong>s<br />
the construction of a coal-fired<br />
power plant, to produce 3,250 MW of<br />
electricity in the first phase, increasing<br />
to 5,250 MW eventually. The power<br />
plant will need 4.5m tpy of coal.<br />
Alcoa and Yangquan Coal<br />
team up for aluminium and<br />
electricity project<br />
Alcoa has entered into a strategic partnership<br />
agreement with Shanxi-based<br />
Yangquan Coal Industry (Group) Co.<br />
to <strong>de</strong>velop an aluminium and electricity<br />
project in Shanxi Province. The<br />
partnership was inked in Taiyuan City<br />
in November, and the two companies<br />
discussed financing, management and<br />
both upstream and downstream <strong>de</strong>velopment<br />
for a future project. Yangquan<br />
Coal is a key coal producer in Shanxi<br />
Province that has long adopted meas-<br />
Rio looking at Emirates smelter with Adbic<br />
Rio Tinto <strong>Alu</strong>minium has formed an alliance<br />
with Abu Dhabi Basic Industries<br />
Group (Adbic) to <strong>de</strong>velop a world-class<br />
aluminium smelter project in Ruwais, Abu<br />
Dhabi. The project has no cost or timetable<br />
yet and remains in the planning phase,<br />
with only pre-feasibility studies by Bechtel<br />
Corp. completed to date. Local reports<br />
suggest a 550,000 tpy smelter at an initial<br />
cost of about US$5bn. Construction could<br />
start in 2008, with production in 2011. The<br />
smelter is the second planned for the largest<br />
of the United Arab Emirates.<br />
Rio eyes greenfield<br />
smelter in Cameroon<br />
Besi<strong>de</strong>s, Rio Tinto Alcan has signed an<br />
amen<strong>de</strong>d agreement with the government<br />
of Cameroon on water resources for<br />
a new 1,000 MW hydro power system in<br />
the West African country. This paves the<br />
way for studies on a potential 400,000 tpy<br />
greenfield smelter. Technical studies are<br />
complete and an energy contract is at the<br />
negotiation stage. A go-ahead <strong>de</strong>cision on<br />
the smelter project is expected by the end<br />
of 2009. The greenfield project is separate<br />
from a previously-agreed brownfield<br />
expansion of the existing E<strong>de</strong>a smelter, a<br />
joint venture between the government<br />
and Rio. The E<strong>de</strong>a brownfield project, lifting<br />
capacity from 90,000 tpy to 300,000<br />
tpy, continues to make progress.<br />
US$8m AP50 fund launched<br />
Rio Tinto Alcan has launched an US$8m<br />
fund in a move to promote competitiveness<br />
among suppliers and contractors<br />
<strong>de</strong>veloping of its AP50 smelting technology<br />
in Quebec’s Saguenay-Lac-Saint-Jean<br />
region. The fund, to be managed by the<br />
Fonds <strong>de</strong> Solidarité <strong>de</strong>s Travailleurs du<br />
Quebec (FSTQ), meets one of Alcan’s commitments<br />
to the government of Quebec in<br />
December 2006 to invest US$2.1bn in the<br />
Saguenay-Lac-Saint-Jean region over ten<br />
years. Rio is proceeding with the construction<br />
of a 60,000 tpy US$550m pilot plant<br />
known as Complexe Jonquière to <strong>de</strong>velop<br />
new smelting technology.<br />
84 ALUMINIUM · 1-2/2008
Photo: AOS<br />
ures to promote its non-coal operations,<br />
and is also backed by abundant<br />
bauxite and energy resources in the<br />
province. Alcoa has also expressed<br />
its confi<strong>de</strong>nce that the Alcoa-Yangquan<br />
Coal tie represents a win-win<br />
situation for both companies, with<br />
Alcoa’s advanced technology and<br />
ALUMINIUM · 1-2/2008<br />
management expertise complementing<br />
its partner’s abundant resource<br />
reserves. Shanxi Province contains<br />
approximately 42.11% of China’s total<br />
bauxite reserves, much of which is<br />
due to be prospected and <strong>de</strong>veloped<br />
in the near future.<br />
�<br />
Bauxite and alumina activities<br />
Dubai investment group<br />
buys German <strong>special</strong>ity<br />
alumina producer<br />
Dubai International Capital (DIC),<br />
which is the private equity arm of<br />
Dubai Holding, acquired the German<br />
<strong>special</strong>ity alumina producer Almatis.<br />
The company is headquartered in<br />
Frankfurt and has eight manufacturing<br />
sites in Germany, the Netherlands,<br />
the USA, Japan, China and India. DIC<br />
paid more than US$1bn for this <strong>de</strong>al. It<br />
has plans to increase capacity by 20%<br />
to around 750,000 tpy by 2010 and is<br />
targeting an aggressive expansion into<br />
<strong>de</strong>veloping markets such as the Gulf<br />
region, India and Brazil. The company’s<br />
growth prospects are robust, as<br />
the majority of future growth in the<br />
alumina refractory market is driven by<br />
global steel volumes produced. DIC is<br />
acquiring Almatis from funds controlled<br />
by Rhone Capital and Teachers’<br />
Private Capital, the investment arm of<br />
the Ontario Teachers’ Pension Plan.<br />
Vietnam to build seven alumina<br />
processing plants by 2015<br />
Vietnam will build seven alumina<br />
refineries and a bauxite-aluminium<br />
processing complex, which will have<br />
a total capacity of 8.4m tpy of alumina<br />
and 0.65m tpy of aluminium hydroxi<strong>de</strong>,<br />
by 2015. The <strong>de</strong>cision to build<br />
these plants follows a government<br />
plan to exploit and process bauxite in<br />
the Central Highlands through 2025.<br />
The plants will cost US$11.8bn-<br />
15.6bn. At least US$47.5m would be<br />
spent on completing the geological<br />
survey, US$9.9-13.7bn for building,<br />
exploiting and processing plants and<br />
US$1.9bn for building infrastructure.<br />
The company <strong>de</strong>veloping the project<br />
will be equitised, with the Vietnamese<br />
government responsible for management.<br />
A <strong>de</strong>dicated port that can load<br />
vessels with 50,000 tonnes of product<br />
will be built in central Binh Thuan<br />
Province to <strong>de</strong>velop the industry in<br />
the Central Highlands and Southern<br />
Central regions. Environmentally<br />
friendly technology will be used to<br />
exploit 5.5bn tonnes of bauxite in the<br />
Central Highlands provinces.<br />
Guangxi Huayin to start<br />
trial production<br />
Guangxi Huayin <strong>Alu</strong>minium Co,<br />
whose backers of the 1.6m tpy alumina<br />
refinery inclu<strong>de</strong> Chalco and China<br />
Minmetals Corp., announced trial<br />
production to start in December 2007.<br />
COMPANY NEWS WORLDWIDE<br />
MRL will purchase the 33% stake China<br />
Minmetals has in Guangxi Huayin<br />
at 855m yuan (US$115m) from parent<br />
company China Minmetals. Minmetals<br />
and Chalco each have a 33% stake<br />
in the project, and Guangxi Investment<br />
Group Corp. owns the remaining<br />
34%. The stake purchase forms<br />
part of Minmetal’s plan to transfer its<br />
alumina and aluminium assets to subsidiary<br />
MRL. Construction of Guangxi<br />
Huayin started in 2005.<br />
Australian bauxite<br />
exploration agreement signed<br />
Hydro is entering into a joint venture<br />
with the Australian mining company<br />
United Minerals Corporation (UMC)<br />
with the intention of recovering bauxite<br />
and producing alumina in Kimberley,<br />
Western Australia. The agreement<br />
gives Hydro a 75% share in the partnership,<br />
which must first finish the<br />
ongoing investigations by the end of<br />
2009 within a total cost framework of<br />
NOK40m (US$7.4m). If the investigation<br />
confirms commercially recoverable<br />
<strong>de</strong>posits the partners will consi<strong>de</strong>r<br />
setting up a mining company and an<br />
alumina company, which may then<br />
result in an investment <strong>de</strong>cision. A<br />
possible bauxite and alumina project<br />
in Australia is in line with Hydro’s<br />
strategy to increase the company’s<br />
primary aluminium production and<br />
step up its production of alumina.<br />
MRN reaches full<br />
bauxite mining capacity<br />
Brazilian bauxite miner Mineração<br />
Rio do Norte (MRN) has reached its<br />
full capacity production of 17.8m tpy.<br />
MRN now expects to stay at this level<br />
for the next 30 to 40 years. The company<br />
in Para state, north Brazil, has<br />
gradually increased its capacity from<br />
16.3m tpy three years ago due to process<br />
improvements. MRN is majorityowned<br />
by CVRD, followed by Alcan,<br />
Alcoa, Norsk Hydro, CBA and BHP<br />
Billiton. MRN may start mining at a<br />
new mine site in or<strong>de</strong>r to ensure continuity<br />
of its current production levels.<br />
The new mine site could involve<br />
a US$100m investment. �<br />
85
COMPANY NEWS WORLDWIDE<br />
Glencore may supply Century<br />
with 2.3m tonnes of alumina<br />
Century <strong>Alu</strong>minum Co., Monterrey,<br />
California, and Glencore International<br />
AG, Zug, Switzerland, have tentatively<br />
agreed on a five-year <strong>de</strong>al for the<br />
supply of 2.3m tonnes of alumina for<br />
Century’s smelters. A final purchase<br />
agreement is pending, according to a<br />
filing ma<strong>de</strong> by Century with the U.S.<br />
Securities and Exchange Commission.<br />
Un<strong>de</strong>r the proposed <strong>de</strong>al, Glencore<br />
would supply Century with 290,000<br />
tonnes of alumina in 2010, 365,000<br />
tonnes in 2011, 450,000 tonnes in<br />
2012 and 2013 and 730,000 tonnes in<br />
2014. The price of the alumina will<br />
be in<strong>de</strong>xed to the price of aluminium<br />
as quoted on the LME. Glencore is<br />
Century’s largest sharehol<strong>de</strong>r, owning<br />
approx. 28.6% of the company’s outstanding<br />
shares. In addition to being<br />
a supplier, the big Swiss tra<strong>de</strong>r is also<br />
a Century customer and a counterpart<br />
to its hedges.<br />
Chinese refineries<br />
to pay more for Bintan bauxite<br />
Chinese alumina refineries will pay<br />
more for bauxite from Bintan, Indonesia,<br />
in 2008, but the increase will pale<br />
in comparison to the rise of freight<br />
costs. Chandong Chiping Xinfa Huayu<br />
<strong>Alu</strong>mina Co. will face an increase of<br />
around US$5-6 per tonne for its 2008<br />
contracts with Bintan miners, This will<br />
take prices next year to around US$20<br />
per tonne fob Bintan for Chiping.<br />
Bauxite prices for Shandong Weigiao<br />
<strong>Alu</strong>minium Co. will not change much<br />
at US$18-22 per tonne fob Bintan next<br />
year. Refineries in China’s eastern<br />
Shandong province are highly <strong>de</strong>pen<strong>de</strong>nt<br />
on imported bauxites, particularly<br />
those from Indonesia. Production cost<br />
increases for refineries are mostly due<br />
to surging freight costs.<br />
Freight costs have risen US$10-<br />
15 per tonne from around mid-year.<br />
Indian bauxite annual contracts are<br />
offered at US$70-90 per tonne cif<br />
Shandong, compared to US$40-50<br />
per tonne cif Shandong in 2006. Bauxite<br />
buyers and sellers typically settle<br />
calendar-year contracts near the end<br />
of the year.<br />
Vietnam licences<br />
US$490m bauxite project<br />
The Vietnam National Coal and Mineral<br />
Industries Group has been awar<strong>de</strong>d<br />
a government licence to <strong>de</strong>velop a<br />
US$490m bauxite mining project in<br />
Lam Dong province in the country’s<br />
central highlands region. The company<br />
is aiming to produce about 600,000<br />
tpy of bauxite with a start-up date in<br />
2010. The Tan Rai bauxite mine in Bao<br />
Lam district is estimated to have a reserve<br />
of over 176m tonnes.<br />
JSW near to winning<br />
approval for alumina refinery<br />
In December JSW <strong>Alu</strong>minium was<br />
close to receiving environmental approval<br />
for its 1.6m tpy alumina refinery<br />
at Visakhapatnamin in the southern<br />
Indian state of Andhra Pra<strong>de</strong>sh.<br />
JSW will use Alcan technology at the<br />
Rs40bn (US$1bn) project. It plans to<br />
set up a refinery in the first phase<br />
along with a 90 MW power plant.<br />
The company will set up a 250,000<br />
tpy aluminium smelter in the second<br />
phase at a cost of Rs60bn (US$1.5bn).<br />
The bauxite mining project that will<br />
feed the alumina refinery is also believed<br />
to have received approval from<br />
the Forest Advisory Committee. JSW<br />
expected to complete a <strong>de</strong>tailed engineering<br />
study for the refinery project<br />
by mid-January and physical work to<br />
start by March or April 2008.<br />
Investors plan US$750m<br />
in African alumina refinery<br />
Investors are in talks with uni<strong>de</strong>ntified<br />
aluminium producers to <strong>de</strong>velop<br />
a US$750m alumina refinery in Sierra<br />
Leone. The plant may be fed with material<br />
from Port Loko, the country’s<br />
largest bauxite <strong>de</strong>posit co-owned by<br />
Boulle and Toronto-based Moydow<br />
Mines International Inc. and Titanium<br />
Resources Ltd.’s nearby Mokanji <strong>de</strong>posit.<br />
The refinery would be built near<br />
the <strong>de</strong>posits northwest of Freetown,<br />
and may yield as much as 1.5m tpy. A<br />
feasibility study could take as much as<br />
18 months. The Port Loko <strong>de</strong>posit contains<br />
about 100m tonnes of bauxite.<br />
�<br />
Recycling and secondary smelting<br />
Alcoa sells autocastings<br />
unit to private equity fund<br />
Alcoa Inc. has sold its automotive<br />
castings business to Compass Automotive<br />
Group LLC, a company owned<br />
by private equity fund Monomoy Capital<br />
Partners LP, New York. Financial<br />
terms were not disclosed. The business<br />
employs about 530 people and<br />
has two main operating locations: the<br />
Michigan Casting Centre in Fruitport,<br />
Michigan, and the Scandinavian Casting<br />
Centre in Farsund, Norway.<br />
Cohen Alloys faces closure<br />
Glasgow-based secondary aluminium<br />
ingot producer Cohen Alloys will close<br />
unless management can raise enough<br />
money to buy the company. The plant<br />
86 ALUMINIUM · 1-2/2008<br />
Photo: Hydro
is located on the Craigton industrial<br />
estate in Glasgow, and the owner of<br />
the estate is believed to be selling the<br />
land. The plant, which is owned by<br />
MacGregor & Moir, produces around<br />
140 tpw of ingot: mainly LM 6 and<br />
LM 25. This closure would reduce the<br />
amount of ingot produced in the UK<br />
by around 5,000 to 6,000 tpy. Cohen<br />
Alloys has assured customers that it is<br />
in business as usual, amid speculation<br />
over the company’s future.<br />
Rio sells Slovenian<br />
castings businesses<br />
In November 2007 Rio Tinto Alcan<br />
sold two automotive casting businesses<br />
in Slovenia to Hidria Rotomatika<br />
d.o.o. Terms of the sale were not<br />
disclosed. The company’s casting<br />
operations in Slovenia employ some<br />
170 people and had 2006 revenue of<br />
US$20m. The two units sold were Alcan<br />
Koper d.o.o., a wholly owned subsidiary<br />
that distributes aluminium die<br />
castings to European automakers, and<br />
Alcan Tomos d.o.o., in which Rio Tinto<br />
Alcan held a 67% stake and which<br />
produces aluminium die castings distributed<br />
through Alcan Koper. The<br />
businesses were no longer a strategic<br />
fit with Rio Tinto Alcan’s Engineered<br />
Products unit. Hidria, based in Spodnja<br />
Idrija in western Slovenia, is using<br />
the acquisition to expand its reach in<br />
the European automotive sector.<br />
Befasa buys Alcasa to form<br />
Europe’s third largest<br />
secondary aluminium producer<br />
Befasa is to buy <strong>Alu</strong>minio Catalan<br />
(Alcasa) to form Europe’s third largest<br />
aluminium waste recycling operation<br />
with capacity to produce<br />
150,000 tpy of secondary aluminium.<br />
The combined company estimates<br />
annual sales at €350m (US$512m)<br />
based on 2006 figures. The company<br />
will be 60% owned by Befasa and 37%<br />
by Qualitas Equity Partners, which<br />
recently bought Alcasa, with the remaining<br />
3% being held by the senior<br />
management. Befasa’s aluminium<br />
division booked sale of €228.4m in<br />
2006 and has 95,000 tpy of aluminium<br />
ALUMINIUM · 1-2/2008<br />
alloy production capacity with sites in<br />
Valladolid and Biscay in Spain, as well<br />
as two salt slag recycling operations in<br />
Spain and the UK with overall treatment<br />
of 20,000 tpy. Alcasa has 55,000<br />
tpy of capacity with sales of €117m<br />
in 2006, with an alloy treatment plant<br />
in Barcelona, and also owns Trinacria,<br />
which has a plant in Krakow, Poland,<br />
and is expected to achieve 20,000 tpy<br />
treatment capacity by 2008.<br />
Chalco expanding<br />
secondary aluminium capacity<br />
In November <strong>Alu</strong>minium Corp. of<br />
China (Chalco) is increasing its secondary<br />
aluminium alloy capacity as<br />
it gets ready to commission and then<br />
expand its Qingdao plant and then<br />
to build another plant in Guangdong<br />
province. Chalco will commission its<br />
100,000 tpy plant in Qingdao in eastern<br />
China’s Shandong province by the<br />
end of 2007. It expects to commission<br />
a second phase of 200,000 tpy – which<br />
will take the capacity of the Qingdao<br />
plant to 300,000 tpy – by 2009. Chalco<br />
is also building another secondary<br />
aluminium alloy plant in Foshan in<br />
southern China’s Guangdong province.<br />
The first phase of 110,000 tpy<br />
is slated for commissioning by the<br />
end of 2008. Capacity of the Foshan<br />
project will ultimately be 300,000 tpy,<br />
but its schedule will <strong>de</strong>pend on the<br />
progress of the first phase.<br />
UK products site to close<br />
Another UK aluminium manufactured<br />
products site at Dolgarrog in Wales<br />
looks set to close after the Welsh regional<br />
government <strong>de</strong>clined to support<br />
a management rescue plan. Dolgarrog<br />
<strong>Alu</strong>minium, which is 100 years<br />
old in 2007, is being wound down by<br />
administrators, although a search for<br />
a potential acquirer continues. The<br />
plant, an integrated casting and rolling<br />
mill, was originally part of Alcoa<br />
but was bought out by its management<br />
around five years ago. Management<br />
wanted to take full control of the<br />
plant but nee<strong>de</strong>d financial assistance<br />
from the regional government, which<br />
<strong>de</strong>clined.<br />
COMPANY NEWS WORLDWIDE<br />
Anglo Blackwells to close<br />
Anglo Blackwells is to close its<br />
Widnes UK facility, after the master<br />
alloys producer filed for administration<br />
in October 2007. The move is part<br />
of a restructuring programme implemented<br />
by its US parent company KB<br />
Alloys. Anglo Blackwells, which was<br />
established as Blackwells Metallurgical<br />
in 1869, was acquired by KB Alloys<br />
in 1995. In 2005, the company<br />
moved most of its business to China,<br />
leaving only a handful of staff at the<br />
Widnes plant in Cheshire.<br />
New Canadian secondary aluminium<br />
plant nears completion<br />
Molten <strong>Alu</strong>minium Producer Canada<br />
(MAPCAN) is nearing completion of<br />
its new secondary aluminium plant<br />
in Allison, Ontario. Mapcan is a joint<br />
venture between Honda Trading<br />
Group and Asahi Seiren Co, and will<br />
supply molten metal to the adjacent<br />
automotive engine plant. Construction<br />
of the new facility was expected<br />
to be mechanically complete by the<br />
end of last year with full production<br />
seen early spring 2008.<br />
Alcoa expands recycling capacity<br />
Alcoa has broken ground on a new<br />
US$22m project at its Can Reclamation<br />
facility at its Tennessee operations.<br />
Improvements inclu<strong>de</strong> a new<br />
crusher, new <strong>de</strong>laquering furnace,<br />
with supporting building enclosures,<br />
utilities and environmental systems.<br />
Implementation of this project will increase<br />
UBC (used beverage can) molten<br />
output capacity by nearly 50%.<br />
Alcoa projects it will recycle nearly<br />
14bn aluminium cans in 2007. The<br />
Can Reclamation project is expected<br />
to be completed over the next 12 to<br />
18 months.<br />
Rio opens new<br />
can recycling plant in France<br />
Rio Tinto Alcan has inaugurated its<br />
US$7m remelting furnace for recycling<br />
used beverage cans (UBC) �<br />
87
COMPANY NEWS WORLDWIDE<br />
and a new US$15m trimming and<br />
slitting machine for beverage can<br />
body stock at its Neuf-Brisach site in<br />
France. Alcan Speciality Sheet operations<br />
inclu<strong>de</strong> rolling and recycling operations<br />
in Neuf-Brisach and Singen<br />
in Germany as well as research and<br />
<strong>de</strong>velopment facilities in Voreppe,<br />
France, and Neuhausen, Switzerland.<br />
China’s output to reach<br />
2.8m tonnes of secondary<br />
aluminium in 2007<br />
China’s total secondary aluminium<br />
production is to reach 2.8m t in 2007,<br />
up from 2.4m tonnes in 2006. Of the<br />
projected amount, about 1.8m tonnes<br />
consist of die casting alloys. In 2008,<br />
output is expected to rise further<br />
to 2.98m tonnes, based on strong<br />
<strong>de</strong>mand and increasing scrap supply.<br />
Demand is expected to grow in<br />
the coming years, e<strong>special</strong>ly in the<br />
manufacturing sectors such as the<br />
automotive industry. Primary aluminium<br />
producers are also looking into<br />
secondary production now. By 2010,<br />
China’s secondary aluminium output<br />
may reach up to 3.6m tonnes.<br />
Alexin building aluminium<br />
billet plant in Indiana<br />
Alexin LLC, a start-up company in<br />
Bluffton, Indiana, has broken ground<br />
on a US$56m aluminium billet casting<br />
facility that is scheduled to be<br />
operational by November 2008. The<br />
plant is expected to produce more<br />
than 95,000 tpy of billet from scrap.<br />
Alexin will offer billet up to 406 mm in<br />
diameter with length up to 7360 mm.<br />
Construction has already begun in<br />
Bluffton, and all equipment has been<br />
or<strong>de</strong>red and will arrive in July 2008.<br />
Alexin will supply billet to soft alloy<br />
extru<strong>de</strong>rs.<br />
Leggett & Platt to sell<br />
aluminium business<br />
Leggett & Platt Inc., Carthage, Missouri,<br />
plans to divest its aluminum<br />
business as part of a broa<strong>de</strong>r strategy<br />
to re-focus the company’s operations.<br />
The new strategy will inclu<strong>de</strong> the divesture<br />
of six other business units as<br />
well. The company expects the sale of<br />
the aluminium business to <strong>de</strong>crease<br />
revenue by approx. US$900m, the<br />
largest chunk of the overall US$1.2bn<br />
Leggett plans to prune overall. Leggett<br />
<strong>de</strong>scribes itself as the leading in<strong>de</strong>-<br />
<strong>Alu</strong>minium semis<br />
North America<br />
Sapa Industrial Extrusions<br />
completes press upgra<strong>de</strong><br />
Sapa Industrial Extrusions has completed<br />
a US$7m rebuilding and upgra<strong>de</strong><br />
of press number nine at its<br />
Cressona, Pennsylvania plant. The<br />
project took almost a year to complete<br />
and inclu<strong>de</strong>d complete disassembly<br />
of the entire press and replacement<br />
of all wearable components. The<br />
equipment employs indirect extrusion<br />
technology with a 5,500 tonne capacity<br />
and 406 mm cylin<strong>de</strong>r size. The<br />
press and its peripheral systems are<br />
now rated to be in ‘as new’ condition.<br />
To improve reliability and control<br />
of temperature and operating speed,<br />
upgra<strong>de</strong>s inclu<strong>de</strong>d significant investment<br />
in a new furnace, press control<br />
valves and programmable logic controls.<br />
Sapa also installed new equipment<br />
for consistent stretch control<br />
and improved handling systems to<br />
protect product finish.<br />
Alcoa Defense awar<strong>de</strong>d contract<br />
for Naval Design Services<br />
Alcoa has been awar<strong>de</strong>d a contract<br />
pen<strong>de</strong>nt producer of non-automotive<br />
die castings in North America. Its aluminium<br />
group has 20 facilities in the<br />
United States and Mexico, including<br />
14 die casting plants, four tool-anddie<br />
shops and two finishing and painting<br />
facilities. Most of the sites are in<br />
the eastern half of the nation. �<br />
from the Naval Surface Warfare Center’s<br />
Car<strong>de</strong>rock Division for <strong>de</strong>sign and<br />
engineering services. These services<br />
will assist in the <strong>de</strong>velopment of selected<br />
assemblies and components<br />
of the Littoral Combat Ship (LCS)<br />
and other naval vessels, particularly<br />
high-speed craft that navigate shallow<br />
waters. The U.S. Congress fun<strong>de</strong>d the<br />
contract in recognition of the <strong>de</strong>sign<br />
and engineering services that Alcoa<br />
Defense has already provi<strong>de</strong>d to the<br />
Army and the Air Force un<strong>de</strong>r the<br />
Army Lightweight Structures Initiative<br />
and the Advance <strong>Alu</strong>minum Aerostructures<br />
Initiative.<br />
Novelis to supply sheet<br />
for GM and Chrysler vehicles<br />
Novelis Inc., Atlanta, will supply aluminium<br />
sheet to General Motors for<br />
the hoods and liftgates on the automaker’s<br />
Chevrolet Tahoe Hybrid<br />
and GMC Yukon hybrid sport utility<br />
vehicles. These two mo<strong>de</strong>ls are the<br />
world’s only full-sized hybrid SUVs.<br />
They weigh about 180 kg less than traditional<br />
mo<strong>de</strong>ls, in part because aluminium<br />
helps to reduce their weight.<br />
<strong>Alu</strong>minium is also used in the vehicles’<br />
hybrid gasoline-electric drive,<br />
88 ALUMINIUM · 1-2/2008<br />
Photo: Hydro
attery back and related equipment.<br />
The company will also supply aluminium<br />
sheet blanks for the hoods of<br />
Chrysler LLC’s 2008 Chrysler Town<br />
& Country and Dodge Caravan minivans.<br />
The contract represents the<br />
first use of aluminium for Chrysler<br />
minivan hoods. The sheet will come<br />
from Novelis’ Oswego/New York and<br />
Kingston/Ontario plants.<br />
Alcoa <strong>de</strong>dicates<br />
new production facility<br />
Alcoa Warrick operations <strong>de</strong>dicated<br />
a new lithographic cleaning line, celebrating<br />
the creation of 50 new jobs<br />
ALUMINIUM · 1-2/2008<br />
at the plant, an additional US$47m to<br />
the local tax base, and a diversification<br />
of products creating a bright future<br />
for the facility. Installation of the<br />
litho line started early in 2007. The<br />
line is <strong>de</strong>signed specifically to clean,<br />
level, and trim lithographic sheet that<br />
is used in the high end printing market<br />
for products including magazines, periodicals,<br />
brochures, and newspaper<br />
inserts.<br />
Rio Tinto Alcan sells majority<br />
of its European Service Centres<br />
Rio Tinto Alcan had received an irrevocable<br />
offer for a substantial ma-<br />
We are one of the world's leading companies in the field of high-temperature technologies and applications.<br />
With a comprehensive portfolio and innovative solutions we take an active part in our customers' future<br />
through a worldwi<strong>de</strong> sales network and service presence in Europe, North America and Asia.<br />
We are looking for internationally experienced candidates (female/male) for the following two functions<br />
High Level Sales Manager<br />
• Responsible for sales of lining products for the<br />
aluminium industry to a <strong>de</strong>fined region and selected<br />
multi-national key accounts<br />
• Negotiate long term supply contracts<br />
• Network with liaison offices and agents<br />
• Organize customers’ audits<br />
• Collaborate with Or<strong>de</strong>r Management, Supply Chain<br />
Management, and Technical Service functions<br />
• Manage contracts with engineering companies<br />
for green field and brown field aluminium smelting<br />
projects<br />
• International sales experience with the aluminum<br />
industry<br />
• Preferably knowledge about use of catho<strong>de</strong> lining<br />
products in primary aluminium smelting pots<br />
• Knowledge of market specific rules and requirements<br />
• Financial and legal un<strong>de</strong>rstanding<br />
• High level of negotiation and communication skills<br />
• Fluent in English and German<br />
Stellenanzeige / Job advertisment<br />
Technical Service Manager<br />
• Provi<strong>de</strong> worldwi<strong>de</strong> technical customer support<br />
and technical sales consulting for selected key<br />
accounts<br />
• Determine customer specific technical<br />
specifications<br />
• Advise, train and support the customers<br />
in product use<br />
• Solve application problems and manage<br />
technical claims<br />
• Collect and benchmark data on product<br />
performance<br />
• Initiate i<strong>de</strong>as for product innovation<br />
• Support sales in assessing the future <strong>de</strong>mand<br />
• Technical education, BS or MS in Engineering:<br />
Metallurgy, Ceramics, Electrical or Chemical<br />
• Professional experience in the primary aluminium<br />
smelting industry or in a related field providing<br />
technical support<br />
• Know-how in smelter <strong>de</strong>signs, technologies and<br />
operations<br />
• Team player with good presentation skills<br />
• Used to working in multicultural environments<br />
• Fluent in English and willing to travel<br />
If you are interested and wish to join a growing global player, please send your complete application, including<br />
resume, information about expected income and availability to the recruiting firm EL-Net Consulting AG.<br />
COMPANY NEWS WORLDWIDE<br />
jority of its European Service Centres<br />
distribution business from Amari Metals.<br />
Amari Metals is a private US-based<br />
company with a significant metal distribution<br />
business. Rio Tinto Alcan’s<br />
aerospace distribution business I is not<br />
inclu<strong>de</strong>d in the transaction. An operation<br />
in Spain is also exclu<strong>de</strong>d. Rio Tinto<br />
Alcan Engineered Products is concentrating<br />
its resources on businesses with<br />
good potential for growth where it can<br />
assume lea<strong>de</strong>rship positions through a<br />
differentiated product offering. Service<br />
Centres business no longer fits in<br />
this strategy. The transaction, which<br />
is subject to competitive review, is<br />
anticipated to close by the end of the<br />
first quarter of 2008. Excluding �<br />
TALENT MAKES CAPITAL DANCE<br />
www.el-netconsulting.com<br />
EL-Net Consulting AG • Schumannstrasse 2 • D-81679 München • Tel: +49 (0)89 45 55 46-0 • Fax: +49 (0)89 45 55 46-10 • mail@el-netconsulting.com<br />
89
COMPANY NEWS WORLDWIDE<br />
the aerospace distribution business<br />
and Spanish operation, Rio’s Service<br />
Centres employ approx. 800 people in<br />
32 sites and 10 countries across continental<br />
Europe. The business recor<strong>de</strong>d<br />
2006 revenues of €340m.<br />
South America<br />
<strong>Alu</strong>casa to boost output in 2008<br />
Venezuelan aluminium company<br />
<strong>Alu</strong>casa aims to reach installed capacity<br />
of 2,000 tpm in 2008 thanks<br />
to, investments in upgra<strong>de</strong>s it plans<br />
to carry out next year. <strong>Alu</strong>casa currently<br />
produces 1,700 to 1,800 tpm of<br />
thin rolled aluminium products. To<br />
reach the goal, <strong>Alu</strong>casa anticipates<br />
investments of roughly US$1.9 million<br />
in technological, environmental<br />
and social upgra<strong>de</strong>s.<br />
Europe<br />
UC Rusal to construct packaging<br />
foil plant in the Moscow region<br />
UC Rusal will construct a packaging<br />
foil plant near the city of Dmitrov in<br />
the Moscow region. The investment<br />
costs are estimated at US$20m. The<br />
plant will have an overall capacity of<br />
20,000 tpy of packaging foil and will increase<br />
UC Rusal’s share of the Russian<br />
foil packaging market by up to 66%.<br />
Construction will begin in 2008 with<br />
first production scheduled for the end<br />
of 2009. The foil for the plant will be<br />
shipped from Armenal, Sayanal, and<br />
Ural foil, UC Rusal’s major foil mills.<br />
The new plant will be equipped with<br />
technologically advance machinery<br />
from the world’s leading manufacturers<br />
of machines used for cutting,<br />
stamping, lamination, and gluing of<br />
foil products.<br />
Irish building claims<br />
two architectural awards<br />
The Source Arts Centre and Library<br />
in Southern Ireland has captured<br />
two major architectural awards. The<br />
new building incorporates a complex<br />
faça<strong>de</strong> <strong>de</strong>sign using Hydro’s Technal-<br />
brand curtain walling. The building<br />
has won an Architectural Association<br />
of Ireland (AAI) Award and the award<br />
for Best Public and Cultural Building,<br />
presented at the Irish Architecture<br />
Awards. Both awards aim to encourage<br />
the highest standards of <strong>de</strong>sign,<br />
while recognizing projects that have<br />
ma<strong>de</strong> a significant contribution to<br />
Irish architecture. The €10m riversi<strong>de</strong><br />
complex, <strong>de</strong>signed by McCullough<br />
Mulvin Architects, has provi<strong>de</strong>d the<br />
local community with a contemporary<br />
and multi-functional building.<br />
It integrates an exhibition space, a<br />
250-seat auditorium and stage, and a<br />
library and media zone.<br />
Alcoa receives<br />
NADCAP certification<br />
Alcoa has received the National Aerospace<br />
and Defence Contractors Accreditation<br />
Program’s (NADCAP) approval<br />
for ultrasonic inspection and<br />
heat-treated forged products at its<br />
Samara manufacturing facility in Russia.<br />
NADCAP is an industry-managed<br />
accreditation programme <strong>de</strong>signed to<br />
<strong>de</strong>velop a global aerospace industry<br />
supplier base with world-class quality<br />
control for <strong>special</strong> processes. The<br />
Samara plant became the second Russian<br />
production facility to acquire the<br />
right to enter the world aerospace<br />
market and work with such customers<br />
as Airbus and Boeing. Alcoa’s Belaya<br />
Kalitva heat-treated sheet and plate<br />
received NADCAP approval in summer<br />
2007.<br />
Russia’s KUMZ lands<br />
Boeing supply agreement<br />
In December JSC Kamensk Uralsk<br />
Metallurgical Works (KUMZ) of Russia<br />
and its U.S. sales agent, A.S. Mill<br />
Products Inc. (ASMP) signed a longterm<br />
supply agreement with Boeing<br />
Commercial Airplanes. KUMZ has<br />
invested more than US$100m over<br />
the past two years upgrading casting,<br />
rolling and heat-treat capabilities at<br />
its Chkalovsky plate facility. The new<br />
plant offers horizontal continuous<br />
heat treatment, electrical conductivity<br />
control, heavy gauge stretching, ultra-<br />
sonic inspection and other supporting<br />
equipment to produce high-quality<br />
aerospace plate products. KUMZ is<br />
the largest in<strong>de</strong>pen<strong>de</strong>nt producer of<br />
semi-finished aluminium products<br />
in Russia and has <strong>de</strong>veloped <strong>special</strong><br />
applications involving aluminiumlithium<br />
alloys. The plant can produce<br />
aluminium sheet up to 2,500 mm wi<strong>de</strong><br />
and 15 m long.<br />
Alcoa <strong>de</strong>livers lightweight<br />
truck bodies to Sip-Well<br />
A team from Alcoa’s Auto and Truck<br />
Structures business in Hungary <strong>de</strong>livered<br />
<strong>special</strong>ly ma<strong>de</strong> new lightweight<br />
aluminium truck bodies in three<br />
months that were <strong>de</strong>signed and built<br />
exactly to customer specifications.<br />
These new truck bodies ma<strong>de</strong> from<br />
aluminium extrusions, castings and<br />
plate from Alcoa Köfem, will save<br />
weight while increasing payload for<br />
Sip-Well of Belgium, a water cooler<br />
company which <strong>de</strong>livers water coolers<br />
and water to the home and office<br />
market segment.<br />
Asia<br />
China Zhongfu mulls<br />
US$740m aluminium plate plant<br />
China’s Zhongfu Industrial Co is consi<strong>de</strong>ring<br />
spending about 5.5bn yuan<br />
(US$740m) to expand and upgra<strong>de</strong><br />
an aluminium plate and strip plant in<br />
China’s central province of Henan. The<br />
mid-sized aluminium smelter controlled<br />
by Dutch-based Vimetco expects<br />
to complete the project in three years.<br />
The plant would have a capacity to<br />
produce 220,000 tpy of aluminium alloy<br />
sheet and strip as well as 80,000<br />
tpy of aluminium medium-thick plate.<br />
This project would replace a 170,000<br />
tpy low-gra<strong>de</strong> aluminium plate and<br />
strip plant, which had already been<br />
un<strong>de</strong>r construction.<br />
Timken supplying<br />
bearings for Chinalco rolling mill<br />
The Timken Co, Canton, Ohio, has<br />
been contracted by Siemens VAI<br />
90 ALUMINIUM · 1-2/2008
metals Technologies Ltd. to supply<br />
bearings for two aluminium rolling<br />
mills un<strong>de</strong>r construction in China<br />
for <strong>Alu</strong>minium Corp. of China (Chinalco).<br />
The terms of the contracts,<br />
which resulted in or<strong>de</strong>rs for Timken’s<br />
large bore cylindrical roller bearings,<br />
were not disclosed. Timken <strong>de</strong>signed<br />
bearings for the two Siemens mills,<br />
enabling the customer to install a<br />
successful recirculation oil system<br />
that improved thermal stability for the<br />
four-row cylindrical bearings.<br />
Sapa seeks to double<br />
capacity at Shanghai plant<br />
Heat exchanger strip maker Sapa is<br />
investing SK430m (US$68m) to double<br />
capacity to 80,000 tpy at its heat<br />
transfer plant in Shanghai, China.<br />
The investment inclu<strong>de</strong>s both property<br />
and machinery. Planning and<br />
procurement are taking place at once<br />
with consi<strong>de</strong>ration for future <strong>de</strong>mands<br />
for heat exchanger material. Another<br />
goal is to increase efficiency at the<br />
heat transfer plant in Shanghai.<br />
Ball to build<br />
beverage can plant in India<br />
Ball Corp., Broomfield, Colorado,<br />
plans to build a beverage can manufac-<br />
The Author<br />
The author, Dipl.-Ing. R. P. Pawlek is<br />
foun<strong>de</strong>r of TS+C, Technical Info Services<br />
and Consulting, Sierre (Switzerland), a<br />
new service for the primary aluminum<br />
industry. He is also the publisher of the<br />
standard works “<strong>Alu</strong>mina Refineries and<br />
Producers of the World” and “Primary<br />
<strong>Alu</strong>minium Smelters and Producers of<br />
the World”. These reference works are<br />
continually updated, and contain useful<br />
technical and economic information<br />
on all alumina refineries and primary<br />
aluminum smelters of the world. They<br />
are available as loose-leaf files and/or<br />
CD-roms from the <strong>Alu</strong>minium-Verlag,<br />
Marketing & Kommunikation GmbH in<br />
Düsseldorf as well as by online or<strong>de</strong>ring<br />
via www.alu<strong>web</strong>.<strong>de</strong> (<strong>Alu</strong>-Bookshop)<br />
from Giesel Verlag GmbH.<br />
ALUMINIUM · 1-2/2008<br />
turing plant in India near Aurangabad<br />
in the state of Maharashtra. The plant<br />
will begin operation by mid 2009 with<br />
one manufacturing line able to produce<br />
approx. 600m cans per year. The<br />
facility will be positioned strategically<br />
to supply two-piece beverage cans for<br />
the majority of existing and currently<br />
planned beverage can filling lines in<br />
India. The plant will be managed by<br />
the company’s wholly owned subsidiary<br />
Ball Packaging Europe.<br />
Chinese aluminium<br />
foil maker cancels IPO<br />
Xiashun Holdings Ltd, China’s largest<br />
maker of aluminium foil used for<br />
food and drink packages, cancelled<br />
a HK$2.1bn (US$270m) Hong Kong<br />
stock sale after the city’s key in<strong>de</strong>x<br />
had its worst month since March<br />
2004. Xiashun pulled the IPO because<br />
of <strong>de</strong>clining market conditions. The<br />
Fujian-based company became the<br />
first since June 2006 to cancel an IPO<br />
in Hong Kong because of <strong>de</strong>clining interest<br />
from buyers. Its <strong>de</strong>cision came<br />
after the Hang Seng In<strong>de</strong>x dropped<br />
Suppliers<br />
Hycast to supply casthouse<br />
equipment for Qatalum<br />
Hycast AS of Sunndalsøra has signed<br />
a letter of intent worth US$40m with<br />
Fata EPC of Italy for the supply of casting<br />
equipment for the new aluminium<br />
smelter to be built in Qatar. The agreement<br />
inclu<strong>de</strong>s <strong>de</strong>sign and supply of<br />
equipment for casting extrusion ingots<br />
and foundry alloys. Construction<br />
of the casthouse is scheduled to begin<br />
in April 2008 and equipment of Hycast<br />
is to arrive in Qatar in December<br />
2008, and will be installed over a period<br />
of one year.<br />
ABB <strong>de</strong>livers gas insulated<br />
substation to EMAL<br />
Power and automation technology<br />
group ABB has been awar<strong>de</strong>d a<br />
US$30 million contract from Emal for<br />
the supply of a gas insulated substa-<br />
COMPANY NEWS WORLDWIDE<br />
8.6% in November and as shares of six<br />
of the nine companies that completed<br />
IPOs in November tra<strong>de</strong> below their<br />
offer price.<br />
Asia <strong>Alu</strong>minium mulls<br />
extrusion facility in Middle East<br />
Asia’s largest aluminium extru<strong>de</strong>r<br />
Asia <strong>Alu</strong>minium Holdings (AAH) is<br />
mulling building an extrusion facility<br />
in the Middle East. Given AAH’s experience<br />
in the business, it could take 12<br />
to 15 months to set up a facility once<br />
a project is <strong>de</strong>ci<strong>de</strong>d. AAH has not settled<br />
on the capacity or location of the<br />
plant but the construction sector in<br />
Dubai is of good size and will continue<br />
to grow in the next five years. There<br />
is also potential in Abu Dhabi, Kuwait<br />
and Qatar. AAH has a total of 300,000<br />
to 350,000 tpy of extruding capacity<br />
in China and recently inaugurated its<br />
Zhaoqing works where it is building a<br />
400,000 tpy hot and cold rolling mill.<br />
The mill is scheduled for full commissioning<br />
by July 2008, after which<br />
it will further raise rolling capacity to<br />
700,000 tpy by 2010.<br />
�<br />
tion (GIS) for the aluminium smelter<br />
of Emirates <strong>Alu</strong>minium Co. (Emal)<br />
which is a joint venture between<br />
Abu Dhabi‘s Mubadala Development<br />
Company and Dubai <strong>Alu</strong>minium<br />
Company (Dubal). Emal’s greenfield<br />
aluminium smelter project has a total<br />
value of US$4.9bn. The smelter is being<br />
built at Al Taweelah, a site close<br />
to Abu Dhabi. Site works on the first<br />
phase of the smelter began early in<br />
2007. In 2010, when the first phase<br />
of the smelter will be completed, it<br />
will start to be operational with a capacity<br />
of approx. 700,000 tonnes per<br />
year. ABB’s contract with Emal within<br />
the first construction phase spans<br />
the supply of a GIS, the <strong>de</strong>livery of<br />
the control and protection system as<br />
well as a substation automation system<br />
(SAS). This smelter project represents<br />
Abu Dhabi‘s entry into the aluminium<br />
industry as it joins the ranks<br />
of major regional and international<br />
producers.<br />
�<br />
91
RESEARCH<br />
Multi-temperature measurement of thermoelectric<br />
power for characterisation of solute levels in<br />
multi-component industrial aluminium alloys<br />
O. Engler, M. Clark, Bonn; L. Löchte, Velbert; Z. Lok, Neuss<br />
The amount of solute elements in<br />
aluminium alloys can be assessed<br />
from measurements of the thermoelectric<br />
power (TEP). Un<strong>de</strong>r<br />
the assumption that the specific<br />
TEP signals of individual alloy<br />
elements in aluminium <strong>de</strong>pend on<br />
temperature in different ways, TEP<br />
values obtained at various temperatures<br />
can provi<strong>de</strong> a number<br />
of in<strong>de</strong>pen<strong>de</strong>nt measurements<br />
for the analysis of solute levels<br />
in multi-component alloys. This<br />
paper <strong>de</strong>scribes an advanced setup<br />
to characterise solute levels<br />
in commercial aluminium alloys<br />
by combining measurements of<br />
the electrical resistivity with TEP<br />
measurements at a number of<br />
sub-ambient temperatures.<br />
Introduction<br />
During industrial processing of aluminium<br />
alloys the level of solute<br />
atoms dissolved in the aluminium<br />
matrix is an important parameter. Elements<br />
in solid solution can increase<br />
the strength of the material, which<br />
is wi<strong>de</strong>ly used e. g. in the non-heat<br />
treatable 5xxx series Al-Mg alloys.<br />
In <strong>de</strong>formed materials, solute elements<br />
may affect softening processes<br />
(recovery and / or recrystallisation).<br />
Second-phase particles, which form<br />
from solid solution, are also known<br />
to exert strong influence on the materials<br />
behaviour during <strong>de</strong>formation<br />
and recrystallisation.<br />
However, although the solute level<br />
is an important microstructure feature<br />
by controlling several materials properties,<br />
its experimental characterisation<br />
is not that simple. The two most<br />
wi<strong>de</strong>ly used techniques inclu<strong>de</strong> measurements<br />
of the electrical resistivity<br />
and the thermoelectric power, TEP.<br />
However, both techniques only yield<br />
an integral value of solutes, but cannot<br />
distinguish between the contribu-<br />
tions of various solute elements. It was<br />
the purpose of the presented study<br />
to combine and advance these two<br />
methods, measurements of electrical<br />
resistivity and TEP measurements at<br />
various sub-ambient temperatures,<br />
into a state that industrial multi-component<br />
alloys can be characterised<br />
with regard to the solute level of up<br />
to eight elements.<br />
The measurement technique<br />
The electrical resistivity, ρ, of an alloy<br />
generally consists of two contributions,<br />
i. e. (i) a temperature-<strong>de</strong>pen<strong>de</strong>nt<br />
term ρ 0 which is in<strong>de</strong>pen<strong>de</strong>nt of<br />
the <strong>de</strong>fect <strong>de</strong>nsity, including solutes,<br />
and (ii) the temperature-in<strong>de</strong>pen<strong>de</strong>nt<br />
contribution of solute elements ρ d .<br />
This empirical observation, known as<br />
Matthiessen’s rule [1, 2], leads to the<br />
following expression of the electrical<br />
resistivity, ρ, of a dilute aluminium alloy<br />
containing several alloy elements i<br />
as a function of temperature, T:<br />
ρ (Τ,c i ss ) = ρ0 (Τ ) + Σα i c i ss + ρother<br />
i<br />
(1)<br />
ρ 0 is the resistivity of high-purity aluminium<br />
(2.65 μΩ·cm at 20°C [3, 4]);<br />
the quantities c i ss indicate the concentration<br />
of element i in solid solution.<br />
The element-specific resistivity<br />
coefficients α i can be found in the literature<br />
(e. g. [1, 4, 5]). The term ρ other<br />
summarises all other contributions<br />
from lattice <strong>de</strong>fects such as vacancies,<br />
dislocations, grain boundaries<br />
and second-phase particles. There<br />
are various means to take such effects<br />
into account (e. g. [4-7]), which,<br />
however, will not be discussed in this<br />
paper any further.<br />
The thermoelectric power, TEP, of<br />
a material is a measure of the magnitu<strong>de</strong><br />
of an induced thermoelectric<br />
voltage in response to a temperature<br />
difference across that material. When<br />
a metal is subjected to a temperature<br />
gradient, electrons at the hot end will<br />
have a higher energy than those at<br />
the cold end and will hence diffuse<br />
towards the cold end so as to lower<br />
the total energy of the system. This<br />
diffusion leads to a drop in electrical<br />
voltage, which counteracts the electron<br />
migration until finally a dynamic<br />
equilibrium is achieved. In case of a<br />
simple geometry as sketched in Fig. 1,<br />
the electrical voltage ΔV is proportional<br />
to the temperature gradient ΔT [8]:<br />
ΔV = SΔT<br />
(2)<br />
Here, S is a constant, which is also<br />
known as the Seebeck coefficient.<br />
This so-called Seebeck effect is most<br />
often used to measure temperatures<br />
by means of thermocouples, where<br />
the thermo-voltage for a given combination<br />
of materials is a measure for<br />
the applied temperature difference.<br />
For analysis of solute elements in<br />
aluminium alloys the inverse effect is<br />
utilised: Here, a constant temperature<br />
Fig. 1: Schematic representation of the<br />
experimental set-up for measuring the<br />
relative TEP ΔV for an aluminium alloy<br />
with respect to high purity aluminium<br />
electro<strong>de</strong>s after applying a temperature<br />
gradient ΔT<br />
92 ALUMINIUM · 1-2/2008<br />
Illustrations: Hydro
gradient of the or<strong>de</strong>r of 10 K is applied<br />
to the sample of interest. The resulting<br />
– rather small – thermo-voltage<br />
is a measure for the amount of lattice<br />
<strong>de</strong>fects and, most notably, alloy elements<br />
in solid solution.<br />
However, as known from thermocouple<br />
measurements, attaching a<br />
voltmeter to the material in or<strong>de</strong>r to<br />
measure the thermoelectric voltage as<br />
sketched in Fig. 1 involves junctions<br />
of different types of metal to another,<br />
so that the measured voltage is a contribution<br />
from the TEP of the material<br />
of interest and that of the electro<strong>de</strong>s.<br />
In the present case the goal is to <strong>de</strong>tect<br />
the amount of the solute alloying<br />
elements in aluminium alloys, so that<br />
the reference electro<strong>de</strong> material was<br />
chosen to be high purity aluminium.<br />
The measured relative TEP, ΔS, is<br />
then given by:<br />
ΔValloy ΔVAl ΔVmeasured ΔS = Salloy - SAl = ⎯⎯⎯ - ⎯⎯ = ⎯⎯⎯⎯<br />
ΔΤ ΔΤ ΔΤ<br />
(3)<br />
Analysis of the TEP signal of a dilute<br />
alloy in terms of the solute concentration<br />
is commonly achieved by applying<br />
the Nordheim-Gorter equation<br />
[8]:<br />
Σi ΔS i α i c i ss<br />
ΔS = ⎯⎯⎯⎯⎯ + ΔS other<br />
ρ (T, c i ss )<br />
(4)<br />
ρ is the electrical resistivity of the alloy<br />
(see Eq. 1); α i and c i ss <strong>de</strong>note the element-specific<br />
resistivity coefficients<br />
and the solute concentration of alloy<br />
element i, respectively. ΔS i are the element-specific<br />
TEP coefficients (see<br />
below), while ΔS other is a correction<br />
term for the influence of other lattice<br />
<strong>de</strong>fects, most notably dislocations.<br />
It has to be noted that both techniques<br />
– measurement of electrical<br />
resistivity and TEP – only yield an integral<br />
value of solutes, but cannot distinguish<br />
between the contributions of<br />
various solute elements. Hence, quantitative<br />
evaluations can only be ma<strong>de</strong><br />
un<strong>de</strong>r the assumption that solely one<br />
element contributes to the signal (e. g.<br />
[9-11]). Combination of the two techniques<br />
will then enable analysing the<br />
contribution of two in<strong>de</strong>pen<strong>de</strong>nt elements<br />
[12, 13]. Similarly, TEP measurements<br />
at two different temperatures<br />
has been shown to yield two in-<br />
ALUMINIUM · 1-2/2008<br />
<strong>de</strong>pen<strong>de</strong>nt signals which, in turn, also<br />
allows analysis on two different solute<br />
elements [13, 14].<br />
In the presented study these i<strong>de</strong>as<br />
were taken further by combining<br />
electrical resistivity measurements<br />
with measurements of TEP at several<br />
sub-ambient temperatures [15] into<br />
a state that industrial multi-component<br />
alloys can be characterised with<br />
regard to their solute level, for up to<br />
eight different alloying elements.<br />
Installation of a<br />
multi-temperature TEP <strong>de</strong>vice<br />
A literature survey has shown that for<br />
Al-Mg-Mn-Fe-Si the individual binary<br />
TEP signals vary significantly with<br />
both solute content and temperature<br />
(Fig. 2). It is important to note that the<br />
manner in which the TEP varies with<br />
T and c i is different for each alloying<br />
element. The mostly non-linear <strong>de</strong>pen<strong>de</strong>nce<br />
on T is seen to dominate at<br />
sub-ambient temperatures and tends<br />
to weaken when higher temperatures<br />
are reached, where the overall linear<br />
T-<strong>de</strong>pen<strong>de</strong>nce of the electrical resistivity<br />
part starts to prevail. Therefore,<br />
TEP values obtained at different subambient<br />
temperatures can in<strong>de</strong>ed<br />
provi<strong>de</strong> the required number of in<strong>de</strong>pen<strong>de</strong>nt<br />
measurements [15].<br />
Based on the above concept, a new<br />
<strong>de</strong>vice was <strong>de</strong>signed, constructed by<br />
Anatech BV, Sittard (the Netherlands)<br />
RESEARCH<br />
[16] and finally installed at the R&D<br />
Center of Hydro <strong>Alu</strong>minium in Bonn,<br />
Germany (Fig. 3). The set-up consists<br />
of two main components, (i) a <strong>de</strong>vice<br />
to establish the temperature and,<br />
most notably, the temperature gradient<br />
along the test specimen and (ii) a<br />
high-precision voltmeter to measure<br />
the resulting low voltage TEP signals<br />
with a resolution of below 0.5 nV.<br />
The Anatech TEP instrument uses<br />
two heat cells which can both be<br />
heated with an electric furnace and<br />
cooled with liquid nitrogen through<br />
a heat exchanger within the furnace<br />
block. Thus, the <strong>de</strong>vice allows measurements<br />
in a temperature range of<br />
–190°C to +400°C with a temperature<br />
stability of better than 0.01 K. The<br />
temperature difference between the<br />
two cells can be controlled between<br />
0 and 20 K, with a typical value of 10<br />
K. Samples with standard geometry<br />
used for resistivity measurements can<br />
be used for the TEP measurements as<br />
well. The samples are clamped with a<br />
small, constant mechanical pressure<br />
on the two high-purity (99.9995%)<br />
aluminium electro<strong>de</strong>s which are in intimate<br />
contact with the two heat cells<br />
(Fig. 4). The TEP signal is then gripped<br />
at these aluminium electro<strong>de</strong>s.<br />
During a typical measurement cycle<br />
a temperature difference of 10 K<br />
is applied to the two ends of the sample,<br />
i. e. to the two furnaces with the<br />
two electro<strong>de</strong>s. The cycle starts at low<br />
Fig. 2. Relative TEP ΔS for binary Al-Mg [8], Al-Mn, Al-Si and Al-Fe [13] as a function of<br />
solute level c i ss measured at various sub-ambient temperatures<br />
93
RESEARCH<br />
temperatures with the one furnace<br />
having a temperature of –175°C and<br />
the other –165°C. This configuration<br />
is kept for a couple of minutes until<br />
the measured TEP signal remains constant.<br />
Then the cells are heated up to<br />
the next measuring temperature, and<br />
this procedure is repeated for seven<br />
temperature combinations from the<br />
above-mentioned average temperature<br />
of –170°C up to room temperature<br />
(25°C). Thus, after one cycle seven<br />
TEP signals for seven temperatures<br />
are acquired.<br />
Unfortunately, only a limited<br />
number of the temperature-<strong>de</strong>pen<strong>de</strong>nt,<br />
element-specific TEP coefficients<br />
ΔS i (T) are available in the literature.<br />
Therefore, in the present study these<br />
parameters had to be measured before<br />
multi-component alloys could<br />
be analysed. For that purpose a set of<br />
binary alloys for the most important<br />
alloying elements, Si, Fe, Cu, Mn, Mg,<br />
Cr, Zn and Ti were produced, solutionised<br />
in or<strong>de</strong>r to generate a condition<br />
with the entire amount of alloying<br />
element in solid solution and finally<br />
water quenched. Then the TEP signals<br />
of the samples were <strong>de</strong>termined<br />
at seven temperatures ranging from<br />
–170°C up to 25°C, in exactly the<br />
same measuring cycle as <strong>de</strong>scribed<br />
above. Finally, for each of these temperatures<br />
and each binary alloy with<br />
a known concentration of solutes the<br />
resulting specific TEP coefficients ΔS i<br />
were calculated with the Nordheim-<br />
Gorter equation (Eq. (4)).<br />
When now an unknown multicomponent<br />
aluminium alloy is probed<br />
at seven temperatures T j , a system of<br />
seven in<strong>de</strong>pen<strong>de</strong>nt equations can be<br />
constructed:<br />
ΔS (T j ) = ΣΔS i T j (c i ss )<br />
t<br />
Fig. 4. Photograph of the specimen clamped on the high-purity aluminium<br />
electro<strong>de</strong>s and the heating / cooling cells ready for the TEP<br />
measurement<br />
Fig. 3. Photograph of the opened TEP <strong>de</strong>vice including the liquid nitrogen tank installed at<br />
Hydro’s R & D Center in Bonn, Germany.<br />
(5)<br />
An additional equation is provi<strong>de</strong>d by<br />
measurement of the electrical resistivity<br />
ρ (Eq. (1)). This set of eight equations<br />
is then solved with the help of a<br />
least-square minimisation algorithm<br />
so as to <strong>de</strong>rive the solute levels c i ss of<br />
up to eight different alloy elements.<br />
Application example<br />
In what follows the application to<br />
multi-component TEP measurements<br />
with the <strong>de</strong>scribed <strong>de</strong>vice will be illustrated<br />
for the<br />
AlFeSi alloy AA<br />
8011, which is<br />
a general-purpose<br />
alloy for<br />
many packagingapplications.<br />
Alloy AA<br />
8011 can be<br />
produced by the<br />
classical route<br />
of direct chill<br />
(DC) casting<br />
followed by hot<br />
and cold rolling<br />
or, alternatively,<br />
by twin roll<br />
casting (TRC)<br />
with subsequent cold rolling. In general,<br />
the TRC process is distinguished<br />
from conventional DC material by a<br />
much higher level of elements in supersaturated<br />
solid solution. Within the<br />
framework of the present study AA<br />
8011 sheet produced by TRC has been<br />
further processed along two routes<br />
differentiated by the amount of solute<br />
elements retained in solid solution: (i)<br />
material processed along route ‘A’ was<br />
cold rolled without inter-annealing,<br />
such that most alloy elements were<br />
retained in solid solution. In contrast,<br />
(ii) material of route ‘B’ was subjected<br />
to a high-temperature inter-annealing<br />
which was accompanied by precipitation<br />
of Si and Fe-bearing particles.<br />
Samples taken at final gauge (90 μm)<br />
were annealed so as to <strong>de</strong>termine the<br />
resistance of the two differently processed<br />
materials to softening. For that<br />
purpose, the samples were slowly heated<br />
up to various temperatures ranging<br />
from 200 to 450°C, kept at this temperature<br />
for 3 hours and finally cooled<br />
down slowly so as to mimic industrial<br />
coil annealing treatments. Fig. 5 shows<br />
the resulting mechanical properties in<br />
terms of yield strength, R p0.2 , and elongation<br />
at fracture, A 100mm , as a function<br />
of the peak metal temperature, MT.<br />
Obviously the two different processes<br />
applied largely influence the response<br />
of the material to annealing. Note that<br />
for back-annealed states (H2x) a flat<br />
softening curve is generally <strong>de</strong>sired<br />
for the sake of process stability.<br />
94 ALUMINIUM · 1-2/2008
For evaluation of the metallurgical<br />
reactions controlling the slope of the<br />
softening curve combined TEP and<br />
resistivity measurements were evaluated<br />
for the as-rolled (fully work<br />
har<strong>de</strong>ned) condition, the results are<br />
summarised in Table 1. It is evi<strong>de</strong>nt<br />
that the solute level of the most important<br />
alloy elements, Si and Fe, is<br />
significantly higher for route ‘A’ than<br />
for route ‘B’. Obviously the high-temperature<br />
inter-annealing performed<br />
in route ‘B’ leads to heavy precipitation<br />
of Si and, particularly, Fe-bearing<br />
phases, not unlike the processes<br />
occurring during homogenisation in<br />
conventional DC processing. With regard<br />
to the final gauge properties the<br />
high level of solute Si and Fe exerts a<br />
strong solute drag retarding the softening<br />
reactions, recovery and recrystallisation,<br />
in the non-inter annealed<br />
material of route ‘A’. Accordingly,<br />
back-annealing of non-inter annealed<br />
TRC sheet at a temperature of about<br />
270°C offers the possibility to attain<br />
material with a strength of about 100<br />
MPa combined with elongation values<br />
in excess of 20%.<br />
Summary and conclusions<br />
This paper <strong>de</strong>scribes an advanced<br />
set-up to characterise solute levels in<br />
aluminium alloys through measurements<br />
of the thermoelectric power<br />
(TEP) at several sub-ambient temperatures.<br />
Un<strong>de</strong>r the assumption that<br />
the specific TEP signals of individual<br />
alloy elements in aluminium display<br />
ALUMINIUM · 1-2/2008<br />
RESEARCH<br />
element Si Fe Cu Mn Mg Cr Zn Ti<br />
bulk composition 0.610 0.910 0.014 0.016 0.0013 0.013 0.005 0.022<br />
solute level, route ‘A’ 0.268 0.046 0.012 0.005 0.0008 0.009 0.004 0.004<br />
solute level, route ‘B’ 0.025 0.004 0.012 0.002 0.0008 0.002 0.004 0.019<br />
Tab. 1: Elements in solid solution for AA 8011, compared to the bulk chemical composition<br />
(in [wt%])<br />
different variation with temperature,<br />
TEP values obtained at various temperatures<br />
can provi<strong>de</strong> a number of<br />
in<strong>de</strong>pen<strong>de</strong>nt measurements for the<br />
analysis of solute levels. In the present<br />
study this i<strong>de</strong>a was implemented by<br />
<strong>de</strong>signing a set-up for automated TEP<br />
measurements in a temperature cycle<br />
from –170°C up to ambient temperature.<br />
In combination with measurements<br />
of the electrical resistivity, TEP<br />
measurements at seven temperatures<br />
allow differentiation of the solute<br />
level of up to eight alloying elements<br />
in commercial multi-component aluminium<br />
alloys.<br />
Acknowledgements<br />
This work was in part fun<strong>de</strong>d by the<br />
German Fe<strong>de</strong>ral Ministry for Education<br />
and Research (BMBF). The authors<br />
are grateful to W. D. Finkelnburg<br />
for helpful discussions.<br />
References<br />
[1] D. Altenpohl, <strong>Alu</strong>minium und <strong>Alu</strong>miniumlegierungen.<br />
Berlin: Springer-Verlag,<br />
1965.<br />
[2] P. Ólafsson, R. Sandström, Å. Karlsson,<br />
Mater. Sci. Forum 217-222 (1996) 981-986.<br />
Fig. 5. Softening diagram for AA 8011 at final foil gauge for two different processing<br />
routes (see text for <strong>de</strong>tails)<br />
[3] J. R. Cooper, Z. Vucic, E. Babic, J. Phys.<br />
F Metal. Phys. 4 (1974) 1489-1499.<br />
[4] F. Kutner, G. Lang, <strong>Alu</strong>minium 52<br />
(1976) 322-326.<br />
[5] J. E. Hatch (ed.), <strong>Alu</strong>minum: Properties<br />
and Physical Metallurgy. Metals Park, OH:<br />
ASM, 1984. 1988<br />
[6] H.-E. Ekström, Back annealing of laboratory<br />
cast AlFeSi and commercial 1200<br />
alloys: I Sample processing, tensile properties<br />
and solute content. Finspång, Swe<strong>de</strong>n:<br />
Sapa technical report D01/699, 2001.<br />
[7] G. Grimvall, Thermophysical Properties<br />
of Materials, p.268, North Holland 1986.<br />
[8] J. M. Pelletier, R. Borrely, Mater. Sci.<br />
Engng. 55 (1982) 191-202.<br />
[9] J. Hasenclever, Einfluß <strong>de</strong>r Fertigungsbedingungen<br />
dünner Bän<strong>de</strong>r auf<br />
Gefüge und mechanische Eigenschaften<br />
von AlMn-1%-Legierungen. Düsseldorf,<br />
Germany: VDI Verlag, 1990.<br />
[10] N. J. Luiggi, Mater. Trans. 28B (1997)<br />
125-133.<br />
[11] S. Tangen, K. Sjølstadt, E. Nes, T.<br />
Furu, K. Marthinsen, Mater. Sci. Forum<br />
396-402 (2002) 469-474.<br />
[12] Z. J. Lok, A. J. E. Flemming, R. G.<br />
Hamerton, S. van <strong>de</strong>r Zwaag, Mater. Sci.<br />
Forum 396-402 (2002) 457-462.<br />
[13] F. R. Boutin, S. Demarkar, B. Meyer,<br />
Proc. 7 th Int. Light Metals Congress,<br />
Leoben/Vienna. Düsseldorf: <strong>Alu</strong>minium-<br />
Verlag, 1987, p. 212-213.<br />
[14] Oscarsson, W. B. Hutchinson, H.-E.<br />
Ekström, D. P. E. Dickson, C. J. Simensen,<br />
G. M. Raynaud, Z. Metallkd. 79 (1988)<br />
600-604.<br />
[15] Z. J. Lok, Microchemistry in <strong>Alu</strong>minium<br />
Sheet Production. PhD-thesis,<br />
Delft University of Technology, Delft, The<br />
Netherlands, 2005.<br />
[16] http://www.anatech.nl/<br />
Authors<br />
Dr. Olaf Engler, senior scientist, and<br />
Michael Clark BSc, technician, are employed<br />
at the R & D Center Bonn of Hydro<br />
<strong>Alu</strong>minium Deutschland GmbH.<br />
Dr. Lothar Löchte, previous programme<br />
manager at Hydro RDB, is now with Erbslöh<br />
<strong>Alu</strong>minium GmbH, Velbert.<br />
Dr. Zacharias Lok, formerly at TU Delft,<br />
now works as a product engineer for can<br />
stock materials at <strong>Alu</strong>minium Norf GmbH,<br />
Neuss, Germany.<br />
95
RESEARCH<br />
Entstehung von CO2-Emissionen bei <strong>de</strong>r<br />
Herstellung von <strong>Alu</strong>minium-Walzprodukten vor <strong>de</strong>m<br />
Hintergrund <strong>de</strong>s nationalen Emissionshan<strong>de</strong>lssystems<br />
J. Neumeister, Neuwied<br />
Ein wesentliches Ziel <strong>de</strong>r <strong>de</strong>rzeitigen<br />
Klimapolitik ist die Reduzierung<br />
entstehen<strong>de</strong>r Treibhausgase.<br />
Mit ihr gingen in <strong>de</strong>r nahen Vergangenheit<br />
unterschiedliche Maßnahmen<br />
einher, um die durch das<br />
Kyoto-Protokoll gesteckten Ziele<br />
bis 2012 erfolgreich einhalten zu<br />
können. Das nationale Emissionshan<strong>de</strong>lssystem<br />
stellt eine dieser<br />
Maßnahmen dar. Hierüber wer<strong>de</strong>n<br />
verschie<strong>de</strong>ne Tätigkeiten <strong>de</strong>r Energiewirtschaft<br />
und <strong>de</strong>r Industrie<br />
bereits durch das Treibhausgas-<br />
Emissionshan<strong>de</strong>lsgesetz erfasst<br />
und unter einen gemeinsamen<br />
CO 2 -Cap gestellt. Um weitere Reduzierungspotenziale<br />
zu erschließen,<br />
beschäftigte sich ein durch die Aleris<br />
<strong>Alu</strong>minium Koblenz GmbH initiiertes<br />
Projekt mit einer Tätigkeit,<br />
die bisher nicht vom nationalen<br />
Emissionshan<strong>de</strong>l erfasst wur<strong>de</strong>,<br />
und zwar <strong>de</strong>r Tätigkeit zur Herstellung<br />
von <strong>Alu</strong>minium-Walzprodukten.<br />
Neben einer ausführlichen<br />
CO 2 -Prozessanalyse relevanter<br />
Herstellungsverfahren und <strong>de</strong>r integrativen<br />
Betrachtung ganzer Prozessketten<br />
wur<strong>de</strong>n Emissionswerte<br />
für unterschiedliche Produkte<br />
entwickelt (vgl. Neumeister 2007).<br />
Diese verhalfen dazu, entsprechen<strong>de</strong><br />
CO 2 -Emissionen, die bei<br />
<strong>de</strong>r Erzeugung von <strong>Alu</strong>minium-<br />
Walzprodukten anfallen, vor <strong>de</strong>m<br />
Hintergrund <strong>de</strong>s nationalen Emissionshan<strong>de</strong>ls<br />
zu beurteilen und zu<br />
bewerten.<br />
Die betrachteten Prozesse bzw. Prozessketten<br />
umfassten sämtliche relevanten<br />
Vorgänge zur Erzeugung von<br />
Bän<strong>de</strong>rn/ Blechen und Platten aus<br />
<strong>Alu</strong>minium. Im Wesentlichen waren<br />
dies Prozesse innerhalb <strong>de</strong>r Betriebsbereiche<br />
Gießerei, Warmwalzwerk,<br />
Kaltwalzwerk und Plattenfertigung.<br />
Zusätzlich wur<strong>de</strong>n noch die Bereitstellung<br />
von Druckluft, Wasser und<br />
<strong>de</strong>r energetische Bedarf von Flurför-<br />
<strong>de</strong>rzeugen analysiert. Die Grenze <strong>de</strong>r<br />
Bilanzierung stellte die Abgrenzung<br />
zur Herstellung von Bän<strong>de</strong>rn/Blechen<br />
und Platten aus <strong>Alu</strong>minium dar. Diese<br />
wur<strong>de</strong>n innerhalb <strong>de</strong>r Fertigungsbereiche<br />
so gewählt, dass Fehler durch<br />
Vernachlässigungen, Ausgrenzungen<br />
und Abschätzungen minimal waren.<br />
Die Grafik (Fig. 1) veranschaulicht<br />
bilanzierte Stoff- und Energieströme<br />
einzelner Prozesse.<br />
Die Betrachtung von Energieverbräuchen<br />
bezog sich im Rahmen <strong>de</strong>r Untersuchungen<br />
ausschließlich auf <strong>de</strong>n<br />
En<strong>de</strong>nergieeinsatz. Der energetische<br />
Einfluss folgen<strong>de</strong>r Punkte fand in<strong>de</strong>s<br />
keine Berücksichtigung:<br />
• benötigte Rohstoffe und entste-<br />
hen<strong>de</strong> Emissionen zur Erzeugung<br />
bzw. Bereitstellung von Erdgas,<br />
Diesel, Wasser und Strom durch<br />
entsprechen<strong>de</strong> Versorgungs-<br />
unternehmen<br />
• benötigte Rohstoffe und entste-<br />
hen<strong>de</strong> Emissionen zur Erzeugung<br />
bzw. Bereitstellung von Primär-<br />
aluminium und weiterer Legie-<br />
rungselemente bzw. von verwen-<br />
<strong>de</strong>tem recycelten <strong>Alu</strong>minium<br />
• menschliche Arbeit, z. B. Maschi-<br />
nenbeschickung von Hand<br />
• metabolische Arbeit, z.B. Nähr-<br />
wert von Lebensmitteln<br />
• Umweltenergie, z. B. natürliche<br />
Beleuchtung o<strong>de</strong>r Beheizung<br />
durch passive Solarenergie-<br />
nutzung.<br />
Die erfassten energetischen Daten<br />
entstan<strong>de</strong>n unter <strong>de</strong>r beson<strong>de</strong>ren<br />
Berücksichtigung eines ausgewählten<br />
Produktionsstandortes. Hierzu<br />
wur<strong>de</strong>n sowohl historische Daten im<br />
Zeitraum zwischen 2000 und 2005<br />
ausgewertet als auch unterschiedliche<br />
Messreihen zur Ermittlung<br />
energetischer Verbräuche herangezogen.<br />
Die hier gezeigten Ergebnisse<br />
basieren auf <strong>de</strong>n genannten Datenerhebungen,<br />
die rund 117 Anlagen<br />
Fig. 1: Darstellung <strong>de</strong>r berücksichtigten Stoff- und Energieströme zur Ableitung <strong>de</strong>r<br />
spezifischen En<strong>de</strong>nergieverbräuche bzw. <strong>de</strong>r entsprechen<strong>de</strong>n spezifischen CO 2 -Emissionen<br />
umfassten, zzgl. bereits existieren<strong>de</strong>r<br />
Studien (u.a. <strong>de</strong>r SFB 525).<br />
Die Bestimmung <strong>de</strong>r einzelnen<br />
CO 2 -Emissionen betrachteter Herstellungsverfahren<br />
erfolgte über die entsprechend<br />
ermittelten spezifischen<br />
En<strong>de</strong>nergieeinsätze. Unterteilt wur<strong>de</strong>n<br />
die entstehen<strong>de</strong>n CO 2 -Emissionen in<br />
prozessbedingte und energiebedingte<br />
Emissionen (vgl. ZUG 2007).<br />
Prozessbedingte Emissionen sind<br />
laut Definition „[...] alle Freisetzungen<br />
von Kohlendioxid in die Atmosphäre,<br />
bei <strong>de</strong>nen das Kohlendioxid als<br />
Produkt einer chemischen Reaktion<br />
entsteht, die keine Verbrennung ist“<br />
(§13 Absatz 2 ZUG 2007). Es konnte<br />
gezeigt wer<strong>de</strong>n, dass bei <strong>de</strong>n betrachteten<br />
Prozessen keinerlei prozessbedingte<br />
Emissionen entstehen.<br />
Energiebedingte Emissionen hingegen<br />
sind verbrennungsbedingte<br />
Emissionen. Die Berechnung dieser<br />
Emissionen erfolgt über eine Aktivitätsrate<br />
und über einen entsprechen<strong>de</strong>n<br />
Emissionsfaktor. Erfolgt die<br />
Bestimmung <strong>de</strong>r CO 2 -Emissionen<br />
96 ALUMINIUM · 1-2/2008
über einen entsprechen<strong>de</strong>n Emissionsfaktor,<br />
so wird weiterhin <strong>de</strong>r<br />
untere Heizwert in Ansatz gebracht.<br />
Wer<strong>de</strong>n die CO 2 -Emissionen über<br />
<strong>de</strong>n Kohlenstoffgehalt bestimmt, so<br />
ist ein Umsetzungsfaktor für CO 2 /C<br />
von 3,664 (EU 2004) anzusetzen. Innerhalb<br />
<strong>de</strong>r Kohlenstoffbilanz wird<br />
dabei zusätzlich zwischen biogenen<br />
und nicht-biogenen Kohlenstoffen<br />
unterschie<strong>de</strong>n. Im Rahmen dieser<br />
Arbeit wur<strong>de</strong> <strong>de</strong>r seitens <strong>de</strong>r Dehst<br />
empfohlene Faktor für Erdgas L mit<br />
0,0002015 t CO2 /kWh th zu Grun<strong>de</strong><br />
gelegt; für Diesel wur<strong>de</strong> ein Emissionfaktor<br />
von 0,000270 t CO2 /kWh th<br />
angewandt. Die hierüber ermittelten<br />
CO 2 -Frachten sind nicht biogen.<br />
Biogene Kohlendioxid-Emissionen<br />
stehen laut Definition für „Emissionen<br />
aus <strong>de</strong>r Oxidation von nicht<br />
fossilem und biologisch abbaubaren,<br />
organischen Kohlenstoff zu Kohlendioxid“<br />
(§2 Absatz 8 ZUV 2007). Mit<br />
an<strong>de</strong>ren Worten: Primärenergieträger<br />
wie Erdöl, Kohle und Erdgas bestehen<br />
aus sogenannten nicht-biogenen<br />
Kohlenstoff laut ZUV 2007 und damit<br />
nach Ansicht <strong>de</strong>r Deutschen Emissionshan<strong>de</strong>lsstelle.<br />
Anhand <strong>de</strong>s jeweiligen Emissionsfaktors<br />
erfolgt dann die Berechnung<br />
<strong>de</strong>r spezifischen CO 2 -Emissionen<br />
über die Anwendung <strong>de</strong>s unteren<br />
Heizwertes und <strong>de</strong>r entsprechen<strong>de</strong>n<br />
spezifischen Aktivitätsrate <strong>de</strong>r jeweiligen<br />
Anlagen.<br />
Als Ergebnis <strong>de</strong>r Prozessanalyse<br />
wur<strong>de</strong>n spezifische CO 2 -Emissionen<br />
unterschiedlicher Anlagen dargestellt<br />
und in verschie<strong>de</strong>nen Produktgruppen<br />
zusammengefasst. Für <strong>de</strong>n Fertigungsbereich<br />
Gießerei wur<strong>de</strong>n<br />
die Arbeitsabläufe <strong>de</strong>s Chargierens,<br />
Schmelzens, Haltens, Refinings, Gießens,<br />
Abschopfens, Fräsens und Plattierens<br />
berücksichtigt (Fig. 2). Anhand<br />
entsprechen<strong>de</strong>r Produktgruppen<br />
wur<strong>de</strong> ersichtlich, dass die entstehen<strong>de</strong>n<br />
CO 2 -Emissionen im Bereich<br />
von 0,017 bis 0,488 t CO2 /t Al liegen. Für<br />
<strong>de</strong>n Bereich <strong>de</strong>s Warmwalzwerkes<br />
wur<strong>de</strong>n die Vorgänge <strong>de</strong>s Erwärmens<br />
und Warmwalzen betrachtet. Das sich<br />
je nach Produktionsstruktur anschließen<strong>de</strong><br />
Kühlen konnte aufgrund unzulänglicher<br />
Daten nicht mit berücksichtigt<br />
wer<strong>de</strong>n. Basierend auf <strong>de</strong>r<br />
sich ergeben<strong>de</strong>n Prozesskette zeigten<br />
ALUMINIUM · 1-2/2008<br />
sich CO 2 -Emissionen von 0,023 bis<br />
0,086 t CO2 /t Al . Der im anschließen<strong>de</strong>n<br />
Schritt betrachtete Fertigungsbereich<br />
<strong>de</strong>s Kaltwalzwerkes beinhaltete die<br />
Prozesse <strong>de</strong>s Vor-, Zwischen- bzw.<br />
Fertigglühens, <strong>de</strong>s Kaltwalzens, <strong>de</strong>s<br />
Längs- und Querteilens, <strong>de</strong>s Reckens<br />
und schließlich <strong>de</strong>s Verpackens. Die<br />
CO 2 -Emissionen lagen hier im Bereich<br />
von 0,002 bis 0,305 t CO2 /t Al .<br />
Schließlich wur<strong>de</strong> noch <strong>de</strong>r Bereich<br />
<strong>de</strong>r Plattenfertigung bilanziert. Die<br />
hierbei untersuchten Prozesse erstrecken<br />
sich auf das Glühen, Kaltwalzen,<br />
Härten, Sägen, Recken und<br />
die Inspektion <strong>de</strong>r Platten. Das sich<br />
ergeben<strong>de</strong> Produktspektrum wur<strong>de</strong><br />
mit Hilfe eines allgemeinen Pro-<br />
RESEARCH<br />
duktansatzes <strong>de</strong>finiert und zeigte im<br />
Gesamten CO 2 -Emissionen von 0 bis<br />
0,409 t CO2 /t Al .<br />
Nach Abschluss <strong>de</strong>r Prozessanalyse<br />
wur<strong>de</strong> ein produktspezifischer<br />
Emissionswertebereich ermittelt.<br />
Dies erfolgte anhand <strong>de</strong>r aufgestellten<br />
spezifischen CO 2 -Emissionen unterschiedlicher<br />
Produktgruppen. Die<br />
gesamten spezifischen CO 2 -Emissionen<br />
<strong>de</strong>r Endprodukte <strong>Alu</strong>miniumband/-blech<br />
bzw. <strong>Alu</strong>miniumplatte<br />
ergaben sich über die unterschiedlichen<br />
Zusammenhänge <strong>de</strong>r einzelnen<br />
Produktgruppen. Der Übersicht<br />
halber wur<strong>de</strong>n diese in Fig. 3 dargestellt.<br />
Hierbei wur<strong>de</strong>n die maximalen<br />
Bereiche <strong>de</strong>r CO 2 -Emissionen be-<br />
Fig. 2: Ergebnis <strong>de</strong>r Prozesskettenanalyse im Fertigungsbereich <strong>de</strong>r Gießerei mit Darstellung<br />
entstehen<strong>de</strong>r CO 2 -Emissionen resultierend aus <strong>de</strong>m jeweiligen spezifischen En<strong>de</strong>nergiebedarf<br />
97
RESEARCH<br />
stimmt. Die ermittelten Bereiche an<br />
Emissionswerten ew Kaltwalzwerk und<br />
ew Plattenfertigung können die Endprodukte<br />
<strong>Alu</strong>miniumband/-blech und<br />
<strong>Alu</strong>miniumplatte repräsentieren.<br />
Hierzu gilt:<br />
ew Al-Band/Blech = (0,042 ÷ 0,879) t CO2 ⁄tAl<br />
ew Al-Platte = (0,04 ÷ 0,983) t CO2 ⁄tAl<br />
mit<br />
ew Al-Band/Blech = Produktspezifischer<br />
Emissionswert für <strong>Alu</strong>miniumbän<strong>de</strong>r/-bleche<br />
in t CO2 /t Al<br />
ew Al-Platte = Produktspezifischer Emissionswert<br />
für <strong>Alu</strong>miniumplatten in<br />
t CO2 /t Al<br />
Weiterhin sollen an dieser Stelle<br />
Einflussgrößen genannt wer<strong>de</strong>n, die<br />
mitunter maßgeblich <strong>de</strong>n zu wählen<strong>de</strong>n<br />
Emissionsbereich in unterschiedlichen<br />
Produktionsstätten beeinflussen.<br />
Diese wären im Einzelnen:<br />
(1) Technologien <strong>de</strong>r vorhan<strong>de</strong>nen<br />
Anlagen. Wesentlich beeinflusst wird<br />
<strong>de</strong>r Emissionswert hierbei durch unterschiedliche<br />
Schmelzanlagen wie<br />
regenerative, rekuperative, Kaltluft-<br />
Brenner und induktive Systeme, aber<br />
auch verwen<strong>de</strong>te Brennertypen an<br />
<strong>de</strong>n eingesetzten Glühöfen<br />
(2) Technischer Zustand <strong>de</strong>r verwen<strong>de</strong>ten<br />
Anlagen. Maßgeblich ist hier<br />
<strong>de</strong>r Zustand <strong>de</strong>r Wärmedämmung<br />
eingesetzter Ofenanlagen, aber auch<br />
<strong>de</strong>r Zustand verwen<strong>de</strong>ter Brenner<br />
(3) Schmelz- und Glühprogramme<br />
nehmen aufgrund unterschiedlicher<br />
Temperaturverläufe und festgelegter<br />
Zeiten Einfluss. Ausschlaggebend ist<br />
an <strong>de</strong>n Schmelzanlagen die vorhan<strong>de</strong>ne<br />
Fuchstemperatur und die gewählte<br />
Überführungstemperatur.<br />
Letztere nimmt wie<strong>de</strong>rum Einfluss<br />
auf <strong>de</strong>n jeweils nachgeschalteten<br />
Halteofen<br />
(4) Produktionsspezfische Einflussgrößen<br />
wie die Auslastung <strong>de</strong>r un-<br />
Fig. 3: Darstellung <strong>de</strong>r Herleitung möglicher Emissionswerte auf Basis <strong>de</strong>r aufgestellten<br />
Produktgruppen<br />
terschiedlichen Anlagen, vorhan<strong>de</strong>ne<br />
Wartezeiten voneinan<strong>de</strong>r abhängiger<br />
Anlagen, unterschiedliche Prozessketten<br />
(5) Legierungen nehmen Einfluss<br />
durch Vorgabe <strong>de</strong>r zu wählen<strong>de</strong>n<br />
Schmelz- und Glühprogramme sowie<br />
die Bestimmung <strong>de</strong>r notwendigen<br />
Walzparameter. Weiterhin sind in<br />
diesem Zusammenhang unterschiedliche<br />
physikalische Eigenschaften<br />
von Be<strong>de</strong>utung<br />
(6) Ausgangsmaterial hat Auswir-<br />
kungen aufgrund <strong>de</strong>r unterschiedlichen<br />
geometrischen Abmessungen<br />
und <strong>de</strong>r hierüber beeinflussten Wärmeübertragungsflächen<br />
innerhalb <strong>de</strong>r<br />
Öfen, aber auch innerhalb weiterer<br />
Prozesse wie <strong>de</strong>r Walzvorgänge, <strong>de</strong>s<br />
Sägens etc.<br />
Zu beachten ist, dass die hier abgebil<strong>de</strong>ten<br />
Emissionswerte <strong>de</strong>n maximal<br />
möglichen Bereich innerhalb <strong>de</strong>r<br />
Produktion von <strong>Alu</strong>minium-Walzprodukten<br />
angeben. Die oben genannten<br />
einschränken<strong>de</strong>n Kriterien sind folg-<br />
2000 2001 2002 2003 2004 2005<br />
tAl 1.420.067 1.431.031 1.544.069 1.596.788 1.632.388 1.693.858<br />
Band/Blech (0,2 – > 6mm)<br />
tCO2 Min.<br />
Max.<br />
59.643<br />
1.248.239<br />
60.103<br />
1.257.876<br />
64.851<br />
1.357.237<br />
67.065<br />
1.403.577<br />
68.560<br />
1.434.869<br />
71.142<br />
1.488.901<br />
tAl 54.146 54.240 64.589 71.350 77.659 77.544<br />
Platten (> 6mm)<br />
tCO2 Min.<br />
Max.<br />
2.166<br />
53.226<br />
2.170<br />
53.318<br />
2.584<br />
63.491<br />
2.854<br />
70.137<br />
3.106<br />
76.339<br />
3.102<br />
76.226<br />
Min. 61.809 62.273 67.434 69.919 71.667 74.244<br />
CO2-Emissionen in Summe tCO2 Max. 1.301.464 1.311.194 1.420.728 1.473.714 1.511.208 1.565.127<br />
Tab. 1: Zusammenstellung <strong>de</strong>r Ergebnisse <strong>de</strong>r Hochrechnung möglicher CO 2 -Emissionen produzierter <strong>Alu</strong>minium-Walzprodukte<br />
auf Basis <strong>de</strong>r Produktionsdaten von 2000 bis 2005 unter Anwendung <strong>de</strong>r aufgestellten Emissionswerte<br />
98 ALUMINIUM · 1-2/2008
lich bei <strong>de</strong>r Wahl <strong>de</strong>s Wertbereichs<br />
heranzuziehen.<br />
Zur Abschätzung <strong>de</strong>r Einflussnahme<br />
<strong>de</strong>r Erzeugung von <strong>Alu</strong>miniumbän<strong>de</strong>rn/-blechen<br />
und -platten auf<br />
die nationale Allokation erfolgte eine<br />
Hochrechnung in Anlehnung an die<br />
laut Gesamtverband <strong>de</strong>r <strong>de</strong>utschen<br />
<strong>Alu</strong>miniumindustrie (GDA) berichteten<br />
Produktionsdaten <strong>de</strong>r <strong>Alu</strong>miniumhalbzeuge.<br />
Die Tab. 1 fasst dies noch<br />
einmal zusammen. Analog zu <strong>de</strong>r Produktionsentwicklung<br />
erzeugter Bän<strong>de</strong>r/Bleche<br />
und Platten verzeichnet<br />
sich ein Anstieg <strong>de</strong>r CO 2 -Emissionen<br />
von 2000 mit maximal erwarteten<br />
1.301.464 t CO2 auf 2005 mit maximal<br />
1.565.127 t CO2 .<br />
Die Ergebnisse machen <strong>de</strong>utlich,<br />
dass es aufgrund <strong>de</strong>s erheblichen<br />
Spektrums an möglichen CO 2 -Emissionen<br />
<strong>de</strong>r unterschiedlichen Produkte<br />
schwer sein wird, diese mittels<br />
eines gemeinsamen Emissionswertes<br />
zusammenzufassen. Im Rahmen <strong>de</strong>s<br />
nationalen Emissionshan<strong>de</strong>ls ist es daher<br />
fraglich, ob eine Vereinheitlichung<br />
bei einer Verpflichtung <strong>de</strong>r <strong>Alu</strong>minium<br />
verarbeiten<strong>de</strong>n Industrie an <strong>de</strong>n<br />
CO 2 -Zertifikatshan<strong>de</strong>l über einen<br />
gemeinsamen Produkt-Emissionswert,<br />
sprich BVT-Produktbenchmark,<br />
erfassbar sein wird. Größere Abweichungen<br />
von einem gemeinsamen<br />
Emissionswert wür<strong>de</strong>n im Rahmen<br />
<strong>de</strong>r Zuteilung zu erheblichen Ungerechtigkeiten<br />
für einzelne Betreiber<br />
führen und somit zu einem wirtschaftlichen<br />
Ungleichgewicht beitragen. Die<br />
politische Ten<strong>de</strong>nz allerdings läuft<br />
<strong>de</strong>rzeit stark auf die Vereinheitlichung<br />
für unterschiedliche Produkte hin.<br />
Für <strong>de</strong>n <strong>Alu</strong>minium verarbeiten<strong>de</strong>n<br />
Prozess bleibt anzuraten, entwe<strong>de</strong>r<br />
auf Basis <strong>de</strong>r hier erzielten Ergebnisse<br />
und zukünftiger Analysen einen<br />
Benchmarkansatz zu entwickeln,<br />
<strong>de</strong>r mittels eines Ausgangswerts ein<br />
eingeschränkteres Spektrum als das<br />
hier ermittelte für eine Zuteilung<br />
von CO 2 -Zertifikaten vorsieht, o<strong>de</strong>r<br />
aber zu versuchen, eine Zuteilung<br />
über die Festlegung unterschiedlicher<br />
Produktgruppen zu erzielen.<br />
Auf Basis <strong>de</strong>r hier ermittelten<br />
CO 2 -Emissionen <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>minium-Walzwerke<br />
soll nun <strong>de</strong>r<br />
Einfluss auf die nationale Allokation<br />
kurz diskutiert wer<strong>de</strong>n. Die Anlagen<br />
ALUMINIUM · 1-2/2008<br />
<strong>de</strong>r <strong>Alu</strong>minium-Walzwerke wären in<br />
diesem Sinne als zusätzliche Neuanlagen<br />
anzusehen. Unter <strong>de</strong>r Annahme<br />
eines konstanten Mengengerüstes bei<br />
vorangegangener Einplanung dieser<br />
Anlagen von rund 11 Mio. t CO2 laut<br />
NAP II soll diese Menge für die weitere<br />
Beurteilung herangezogen wer<strong>de</strong>n.<br />
Ebenfalls wird bei <strong>de</strong>r Betrachtung<br />
sowohl von <strong>de</strong>n maximal als<br />
auch minimal möglichen CO 2 -Emissionen<br />
ausgegangen. Bezieht man diese<br />
für 2005 ermittelten CO 2 -Emissionen<br />
von 74.244 t CO2 bis 1.565.127 t CO2 auf<br />
<strong>de</strong>n laut ZUG 2012 vorgegebenen<br />
CAP für zusätzliche Anlagen, so ergibt<br />
sich ein Anteil von rund 0,67 bis<br />
14,2%. Dies wür<strong>de</strong> be<strong>de</strong>uten, dass bei<br />
<strong>de</strong>n jährlichen Zertifikatsmengen <strong>de</strong>r<br />
Jahre 2008 bis 2012 für die zusätzlichen<br />
Anlagen bis 14,2% <strong>de</strong>r Mengen<br />
auf die <strong>de</strong>utschen <strong>Alu</strong>minium-Walzwerke<br />
entfallen könnten.<br />
Legt man an dieser Stelle das ermittelte<br />
Maximum <strong>de</strong>r hochgerechneten<br />
CO 2 -Emissionen für eine Zuteilung<br />
ohne die Berücksichtigung etwaiger<br />
anteiliger Kürzungen zu Grun<strong>de</strong><br />
und stellt dieses <strong>de</strong>n übrigen Tätigkeiten<br />
nach TEHG 2004 für das Jahr<br />
2005 gegenüber (vgl. Tab. 2), so lässt<br />
sich erkennen, dass die angefallenen<br />
Mengen, zusammen mit <strong>de</strong>n aus <strong>de</strong>n<br />
keramischen Erzeugnissen und <strong>de</strong>r<br />
Zellstoffproduktion resultieren<strong>de</strong>n<br />
Emissionen, im unteren Bereich zu<br />
fin<strong>de</strong>n sind.<br />
Hierbei darf nicht außer Acht gelassen<br />
wer<strong>de</strong>n, dass Tätigkeiten wie<br />
die Erzeugung von Zellstoff mit rund<br />
305.828 t CO2 bereits am Han<strong>de</strong>lssystem<br />
teilnehmen und somit aktiv an<br />
<strong>de</strong>r Einhaltung <strong>de</strong>r getroffenen Min<strong>de</strong>rungspflichten<br />
mitwirken. Kuhn/<br />
RESEARCH<br />
Tätigkeit CO2- Emissionen [tCO2/a] Feuerungsanlagen 380.531.645<br />
Roheisen und Stahl 32.155.159<br />
Raffinerien 23.761.135<br />
Zementklinker 20.433.336<br />
Kalk 9.672.669<br />
Papier, Karton, Pappe 4.710.677<br />
Glas 3.928.428<br />
Keramische Erzeugnisse 1.883.097<br />
<strong>Alu</strong>minium Walzprodukte 1.565.127<br />
Zellstoff 305.828<br />
Tab. 2: Gegenüberstellung <strong>de</strong>r maximal erwarteten CO 2-Zertifikatsmengen für die Tätigkeit<br />
<strong>de</strong>r Erzeugung von <strong>Alu</strong>minium-Walzprodukten im Jahr 2005 zu <strong>de</strong>n weiteren Tätigkeiten<br />
im nationalen Emissionshan<strong>de</strong>l nach TEHG 2004.<br />
Thielen 2003 berufen sich in diesem<br />
Zusammenhang auf die Min<strong>de</strong>rung<br />
spezifischer CO 2 -Emissionen und<br />
die hierüber eingehaltene Selbstverpflichtung<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
am Beispiel <strong>de</strong>r Firma <strong>Alu</strong>minium<br />
Norf GmbH in Neuss. Eine Min<strong>de</strong>rung<br />
<strong>de</strong>r CO 2 -Emissionen bezieht sich im<br />
Sinne <strong>de</strong>s nationalen Emissionshan<strong>de</strong>ls<br />
allerdings nicht auf spezifische<br />
CO 2 -Emissionen, son<strong>de</strong>rn stets auf<br />
absolute Mengen. Die Senkung <strong>de</strong>r<br />
spezifischen CO 2 -Emissionen ist somit<br />
stets <strong>de</strong>r Entwicklung <strong>de</strong>r Produktionsmengen<br />
gegenüberzustellen.<br />
Die durchgeführte Bilanzierung am<br />
Beispiel <strong>de</strong>s betrachteten <strong>Alu</strong>minium-Walzwerkes<br />
hingegen zeigte eine<br />
jährliche Zunahme <strong>de</strong>r gesamten<br />
CO 2 -Emissionen im Mittel <strong>de</strong>r Jahre<br />
2000 bis 2006 von rund 1,4%.<br />
Abschließend ist festzuhalten,<br />
dass eine mögliche Teilnahme <strong>de</strong>r<br />
Tätigkeiten zur Erzeugung von <strong>Alu</strong>minium-Walzprodukten<br />
keine gravieren<strong>de</strong><br />
Auswirkung auf die gesamte<br />
nationale Allokation haben wird. So<br />
könnte sich diese allerdings in <strong>de</strong>r Anpassung<br />
<strong>de</strong>s zugrun<strong>de</strong> gelegten Erfüllungsfaktors<br />
äußern. Die zusätzlichen<br />
Mengen wären mitunter auf die bisher<br />
teilhaben<strong>de</strong>n Unternehmen umzulegen.<br />
Inwiefern dies hin zu einer<br />
verstärkten Verkürzung <strong>de</strong>s Marktes<br />
führt, bleibt abzuwarten. Vermutlich<br />
wer<strong>de</strong>n zusätzlich über CDM- und<br />
JI-Maßnahmen generierte Zertifikate,<br />
die innerhalb <strong>de</strong>r zweiten Han<strong>de</strong>lsperio<strong>de</strong><br />
von 2008 bis 2012 bis zu einem<br />
Anteil von 22% (vgl. ZUG 2012 §18<br />
Satz 1) genutzt wer<strong>de</strong>n können um<br />
die Abgabepflicht zu erfüllen, diesen<br />
Verkürzungseffekt ausgleichen.<br />
Eine im Rahmen dieses Projektes<br />
99
NEW BOOKS<br />
entstan<strong>de</strong>ne Dissertation mit <strong>de</strong>m<br />
Thema „CO 2 -Prozessanalyse von<br />
<strong>Alu</strong>minium-Walzprodukten und Ansätze<br />
für eine CO 2 -arme Produktion“<br />
(Neumeister 2007) wird En<strong>de</strong> <strong>de</strong>s<br />
ersten Quartals 2008 veröffentlicht.<br />
Diese beschäftigt sich neben <strong>de</strong>r hier<br />
erwähnten Ableitung von Emissionswerten<br />
für <strong>Alu</strong>minium-Walzprodukte<br />
auch hinsichtlich <strong>de</strong>r Einhaltung <strong>de</strong>s<br />
nationalen Klimaschutzziels mit Möglichkeiten<br />
<strong>de</strong>r CO 2 -Min<strong>de</strong>rung innerhalb<br />
<strong>de</strong>r Produktionabläufe von <strong>Alu</strong>minium-Walzwerken<br />
und berücksichtigt<br />
dabei auch erstmals die Anwendung<br />
einer CO 2 -Abscheidung. Diese Thematik<br />
wird in <strong>de</strong>r nächsten Ausgabe<br />
dieser Zeitschrift aufgegriffen.<br />
Quellen<br />
(1) ZUG 2007: „Gesetz über <strong>de</strong>n nationalen<br />
Zuteilungsplan für Treibhausgas-Emissionsberechtigungen<br />
in <strong>de</strong>r Zuteilungsperio<strong>de</strong><br />
2005 bis 2007“, Bun<strong>de</strong>sgesetzblatt, Jg.<br />
2004, Teil I Nr. 45, Bonn 30.08.2004.<br />
(2) ZUG 2012: „Gesetz zur Än<strong>de</strong>rung <strong>de</strong>r<br />
Rechtsgrundlagen zum Emissionshan<strong>de</strong>l<br />
im Hinblick auf die Zuteilungsperio<strong>de</strong><br />
2008 bis 2012“, Bun<strong>de</strong>sgesetzblatt, Jg.<br />
2007, Teil I Nr. 38, Bonn 10.08.2007.<br />
(3) ZUV 2007: „Verordnung über die Zuteilung<br />
von Treibhausgas-Emissionsberechtigungen<br />
in <strong>de</strong>r Zuteilungsperio<strong>de</strong> 2005<br />
bis 2007“, Bun<strong>de</strong>sgesetzblatt, Jg. 2004, Teil<br />
I Nr. 46, Bonn 31.08.2004.<br />
(4) TEHG 2004: „Gesetz zur Umsetzung<br />
<strong>de</strong>r Richtlinie 2003/87/EG über ein System<br />
für <strong>de</strong>n Han<strong>de</strong>l mit Treibhausgasemissionszertifikaten<br />
in <strong>de</strong>r Gemeinschaft“,<br />
Bun<strong>de</strong>sgesetzblatt, Jg. 2004, Teil I<br />
Nr. 35, Bonn 14.07.2004.<br />
(5) Kuhn; Thielen 2003: „Fachberichte-<br />
Energieeinsparung und CO 2-Min<strong>de</strong>rung<br />
in einem integrierten <strong>Alu</strong>minium-Walzwerk“,<br />
P. Kuhn, St. Thielen, in: Gaswärme<br />
International, Bd. 52 Nr. 8, Gaswärme Institut,<br />
Essen 2003, S.508- 514.<br />
(6) EU 2004: „Entscheidung <strong>de</strong>r Komission<br />
vom 29/01/2004 zur Festlegung von Leitlinien<br />
für Überwachung und Berichterstattung<br />
betreffend Treibhausgasemissionen<br />
gemäß <strong>de</strong>r Richtlinie 2003/87/EG <strong>de</strong>s<br />
Europäischen Parlaments und <strong>de</strong>s Rates“,<br />
Komission <strong>de</strong>r Europäischen Union, Brüssel<br />
29.01.2004.<br />
(7) Neumeister 2007: „CO 2-Prozessanalyse<br />
von <strong>Alu</strong>minium-Walzprodukten und<br />
Ansätze für eine CO 2-arme Produktion“,<br />
J. Neumeister, Eingereichte Dissertation<br />
an <strong>de</strong>r Fakultät für Maschinenwesen <strong>de</strong>r<br />
Ruhr Universität Bochum, Bochum 2007.<br />
(8) Son<strong>de</strong>rforschungsbereich SFB 525,<br />
Ressourcenorientierte Gesamtbetrach tung<br />
von Stoffströmen metallischer Rohstoffe,<br />
RWTH Aachen, 1997-2002, Aachen.<br />
Autor<br />
Pre-painted <strong>Alu</strong>minium in Exterior Architecture<br />
This book is meant to be an introduction<br />
to a subject, which so<br />
far has not been covered in <strong>de</strong>tail<br />
in technical or architectural professional<br />
literature. The segment<br />
of surface-treated, semi-finished<br />
aluminium rolled products for<br />
high-tech, post-formable architectural<br />
applications since more than<br />
40 years has grown into a sizable<br />
business and has increased substantially<br />
in complexity.<br />
Conventional education on the engineering<br />
or architectural si<strong>de</strong> can<br />
hardly cope with the pace of new<br />
i<strong>de</strong>as and <strong>de</strong>velopments constantly<br />
coming up in this innovative industry.<br />
Therefore, the book is inten<strong>de</strong>d to<br />
provi<strong>de</strong> a not too scientific, up-to-date<br />
and systematic overview (as of 2007)<br />
of facts and data compiled from various<br />
sources. Also, mo<strong>de</strong>rn means of<br />
information have been integrated for<br />
further studies or research of the latest<br />
<strong>de</strong>velopments by means of electronic<br />
means (internet research / email addresses)<br />
via respective tra<strong>de</strong> names or<br />
relevant industry publications, which<br />
usually tend to be close to the latest<br />
<strong>de</strong>velopments.<br />
The book can be used as reference<br />
and study gui<strong>de</strong> by a wi<strong>de</strong> range of<br />
professionals. The focus is on architects,<br />
specifiers, planners, consultants,<br />
building owners, metal buil<strong>de</strong>rs or<br />
procurement personnel as well as on<br />
apprentices, trainees and newcomers<br />
to the subject. A general overview is<br />
given about the specific range of prepainted<br />
aluminium rolled products<br />
for exterior architecture from fabrication<br />
of the semi-finished product to<br />
installation of the finished products.<br />
Rea<strong>de</strong>rs will become familiar with the<br />
comprehensive technical terms used<br />
in this market segment, while <strong>de</strong>cision<br />
makers will be enabled to differentiate<br />
between the options between<br />
respective technologies and qualities<br />
Dipl.-Ing. Jens Neumeister studierte Maschinenbau<br />
an <strong>de</strong>r Fachhochschule Koblenz<br />
(Vertiefungsrichtung Energie- und<br />
Umwelttechnik), mit nachfolgen<strong>de</strong>m<br />
Er gänzungsstudium an <strong>de</strong>r Technischen<br />
Uni versität Clausthal. Sein Promotionsverfahren<br />
zum Dr.-Ing. wird in Kürze abgeschlossen<br />
sein. Seit 2006 betreibt er das<br />
Ingenieurbüro Neumeister in Neuwied<br />
mit <strong>de</strong>n Schwerpunkten energetische<br />
Beratung im industriellen Kraftwerksbereich/Papierindustrie<br />
sowie Unternehmensbetreuung<br />
im CO 2-Zertifikathan<strong>de</strong>l.<br />
In <strong>de</strong>r Zeit von 2006 bis zum Jahreswechsel<br />
2008 war Neumeister in <strong>de</strong>r Abteilung<br />
„Technische Dienste“ <strong>de</strong>r Aleris <strong>Alu</strong>minium<br />
Koblenz GmbH in Koblenz tätig, in <strong>de</strong>r<br />
er das hier vorgestellte Projekt leitete. In<br />
dieser Zeit schrieb er seine Dissertation,<br />
die vom Lehrstuhl für Energiesysteme und<br />
Energiewirtschaft <strong>de</strong>r Ruhr-Universität<br />
Bochum betreut wur<strong>de</strong>.<br />
resulting from that.<br />
An insight is being given into the<br />
versatility of pre-painted aluminium<br />
for roof and wall claddings. The variety<br />
of applications is shown to un<strong>de</strong>rstand<br />
the technical aspects, which<br />
should lead to economical construc-<br />
100 ALUMINIUM · 1-2/2008
tions with their specific advantages<br />
of pre-painted rolled products versus<br />
other options. There are differences<br />
in <strong>de</strong>signs, product philosophies and<br />
qualities leading to individual solutions<br />
and price levels of the end products<br />
installed.<br />
As pre-painted aluminium sheets<br />
are expected to have a larger share in<br />
architecture than before this book is<br />
inten<strong>de</strong>d to illustrate the advantages<br />
Handbuch zur Industriellen Bildverarbeitung<br />
Die Fraunhofer-Allianz Vision, Erlangen,<br />
hat anlässlich ihres 10-jährigen<br />
Jubiläums das „Handbuch<br />
zur Industriellen Bildverarbeitung<br />
– Qualitätssicherung in <strong>de</strong>r Praxis“<br />
herausgegeben. Das Buch<br />
gibt einen Überblick über die industrielle<br />
Qualitätssicherung mit<br />
automatischer Bildverarbeitung<br />
und ist sowohl zur Unterstützung<br />
von Entscheidungsträgern als auch<br />
von Anwen<strong>de</strong>rn gedacht. Neben<br />
Fachaufsätzen komplettieren eine<br />
Anbieterübersicht und ein Referenzteil<br />
zu Fachliteratur, Fachzeitschriften,<br />
Messen, Veranstaltungen<br />
usw. das Handbuch.<br />
Die Leitfa<strong>de</strong>n-Reihe zur Bildverarbeitung<br />
<strong>de</strong>r Fraunhofer-Allianz Vision<br />
hat sich in <strong>de</strong>n letzten Jahren fest<br />
etabliert. In <strong>de</strong>r Vergangenheit wur<strong>de</strong><br />
jährlich ein Leitfa<strong>de</strong>n herausgegeben,<br />
<strong>de</strong>r jeweils einen Aspekt neuer<br />
Entwicklungen in <strong>de</strong>r industriellen<br />
Bildverarbeitung in möglichst verständlicher<br />
Form unter Einbindung<br />
von Praxisbeispielen beleuchtet hat.<br />
Anlässlich <strong>de</strong>s 10-jährigen Jubiläums<br />
<strong>de</strong>r Allianz erscheint statt eines Leitfa<strong>de</strong>ns<br />
dieses komplette Buch, das<br />
das aktuelle Wissen <strong>de</strong>r industriellen<br />
Bildverarbeitung bün<strong>de</strong>lt. Beson<strong>de</strong>re<br />
Beachtung fin<strong>de</strong>n auch die zukunftsträchtigen<br />
und noch nicht so verbreiteten<br />
Techniken zur Inspektion unter<br />
<strong>de</strong>r Oberfläche und zur berührungslosen<br />
dreidimensionalen Vermessung<br />
von Werkstücken bis in <strong>de</strong>n Nanometerbereich<br />
<strong>de</strong>r Oberflächenstrukturen.<br />
Das Buch bietet eine anwendungsbezogene<br />
Mischung aus Theorie und<br />
ALUMINIUM · 1-2/2008<br />
of pre-painted aluminium rolled<br />
products, <strong>de</strong>signed for <strong>de</strong>corative<br />
purposes. Rea<strong>de</strong>rs will profit from<br />
this accumulated know-how and be<br />
encouraged to consi<strong>de</strong>r pre-painted<br />
aluminium sheets to be an interesting<br />
and advantageous option in their<br />
planning consi<strong>de</strong>rations for exterior<br />
roof and wall claddings.<br />
The author Fred-Ro<strong>de</strong>rich Pohl is<br />
an acknowledged expert whose busi-<br />
Praxis. Die Beiträge stammen von erfahrenen<br />
Wissenschaftlern und sind<br />
nicht nur für Anwen<strong>de</strong>r, son<strong>de</strong>rn<br />
auch für Ingenieure und Studieren<strong>de</strong><br />
interessant, bei <strong>de</strong>nen Überlegungen<br />
zum praktischen Einsatz <strong>de</strong>r Techniken<br />
in <strong>de</strong>r industriellen Umgebung<br />
im Vor<strong>de</strong>rgrund stehen.<br />
Im ersten Teil wer<strong>de</strong>n zunächst einige<br />
Grundlagen <strong>de</strong>r Bildverarbeitung<br />
vorgestellt. Der Bogen spannt sich von<br />
technischen Voraussetzungen über<br />
Wirtschaftlichkeitsbetrachtungen bis<br />
hin zu praktischen Tipps für <strong>de</strong>n Einsatz<br />
von Bildverarbeitungssystemen<br />
im Betrieb. Es folgen ein Überblick<br />
über momentan verfügbare Bild-Sensoren<br />
(Zeile, Matrix, CMOS, Röntgen,<br />
3-D, Infrarot usw.) sowie über Optiken<br />
und Beleuchtung. Abgeschlossen wird<br />
<strong>de</strong>r erste Teil mit Betrachtungen zum<br />
Thema Software.<br />
Die folgen<strong>de</strong>n Kapitel behan<strong>de</strong>ln<br />
anwendungsbezogene Themen. Die<br />
Einteilung orientiert sich an <strong>de</strong>r Fragestellung,<br />
was bzw. welcher Bereich<br />
von Werkstücken geprüft wer<strong>de</strong>n<br />
soll (also Oberflächen, Abmessungen<br />
usw.) und wie (also mit welcher Prüfmetho<strong>de</strong>)<br />
die Prüfung stattfin<strong>de</strong>n soll.<br />
Zunächst geht es um die äußerliche<br />
Prüfung von Werkstücken: Oberflächenprüfung<br />
und Charakterisierung<br />
von Mikrostrukturen auf Oberflächen.<br />
Danach wer<strong>de</strong>n Metho<strong>de</strong>n<br />
<strong>de</strong>r berührungslosen Messtechnik<br />
vorgestellt, mit <strong>de</strong>nen Werkstücke<br />
dreidimensional vermessen und auf<br />
Maßhaltigkeit geprüft wer<strong>de</strong>n können.<br />
Anschließend wer<strong>de</strong>n dann<br />
Metho<strong>de</strong>n beschrieben, mit <strong>de</strong>nen<br />
man Bereiche in Werkstücken, die<br />
äußerlich nicht sichtbar sind, unter-<br />
NEUE BÜCHER<br />
ness career has been closely connected<br />
with the promotion of pre-painted<br />
aluminium for architectural purposes<br />
for many <strong>de</strong>ca<strong>de</strong>s.<br />
F.-R. Pohl, Pre-Painted <strong>Alu</strong>minium<br />
in Exterior Architecture, ISBN 978-<br />
87017-288-6, 1. edition 2007, 160 p., €<br />
67,- plus shipping costs. This book can<br />
also be or<strong>de</strong>red via Giesel Verlag <strong>web</strong>site:<br />
www.alu<strong>web</strong>.<strong>de</strong> (<strong>Alu</strong>-Bookshop).<br />
suchen kann. Zum einen können mit<br />
Wärmefluss-Thermographie Fehler<br />
unterhalb <strong>de</strong>r Oberfläche <strong>de</strong>tektiert<br />
o<strong>de</strong>r auch Schichtdicken vermessen<br />
wer<strong>de</strong>n. Zum an<strong>de</strong>ren erlaubt die<br />
Röntgentechnik die Untersuchung<br />
und Vermessung <strong>de</strong>s Inneren von<br />
Werkstücken. Schließlich wird noch<br />
ein Blick in die Zukunft geworfen:<br />
Die Terahertz-Tomographie befin<strong>de</strong>t<br />
sich noch im Entwicklungsstadium,<br />
verspricht aber für die Zukunft interessante<br />
und insbeson<strong>de</strong>re die Röntgentechnik<br />
ergänzen<strong>de</strong> Perspektiven,<br />
<strong>de</strong>nn THz-Strahlung durchdringt Papier,<br />
Keramiken und Kunststoffe und<br />
wird von metallischen Leitern und<br />
Wasser absorbiert. Vorteilhaft gegenüber<br />
Röntgenstrahlung ist, dass diese<br />
Strahlung extrem energiearm und somit<br />
nichtionisierend ist.<br />
Im Anschluss an <strong>de</strong>n Textteil<br />
folgt das Kapitel „Anbieter-Porträts“.<br />
Maßgebliche Firmen, die Systeme<br />
und Lösungen zur Bildverarbeitung<br />
und optischen Messtechnik anbieten,<br />
wer<strong>de</strong>n hier in standardisierter<br />
Form porträtiert, so dass <strong>de</strong>r Leser<br />
bei Bedarf geeignete Kontaktdaten<br />
und Adressen zur Hand hat. Den<br />
Abschluss bil<strong>de</strong>t das Kapitel „Referenzen“<br />
mit einer Zusammenstellung<br />
wichtiger Quellen zur Bildverarbeitung<br />
wie Fachliteratur, Zeitschriften,<br />
Messen und Veranstaltungen.<br />
Handbuch zur Industriellen Bildverarbeitung<br />
– Qualitätssicherung in <strong>de</strong>r<br />
Praxis, Fraunhofer IRB Verlag, 513<br />
S., geb., 4-farbig, ISBN: 978-3-8167-<br />
7386-3, Preis € 52,00. Bezug: Büro <strong>de</strong>r<br />
Fraunhofer-Allianz Vision (vision@<br />
fraunhofer.<strong>de</strong>) o<strong>de</strong>r Buchhan<strong>de</strong>l.<br />
101
VERANSTALTUNGEN<br />
Review<br />
Incal 2007 – 3rd International Conference on <strong>Alu</strong>minium<br />
21 to 23 November 2007, Hy<strong>de</strong>rabad, India<br />
In his keynote address Presi<strong>de</strong>nt<br />
of <strong>Alu</strong>minium Association of India,<br />
Debu Bhattacharya (also Managing<br />
Director of Hindalco Industries<br />
Ltd., the aluminium major in<br />
India) spoke about India’s role in<br />
the aluminium world of tomorrow.<br />
He referred to India as a <strong>de</strong>sired<br />
<strong>de</strong>stination, the attractiveness of<br />
India as a manufacturing centre<br />
and the aluminium industry’s role<br />
in India. The attractiveness of the<br />
aluminium industry in India and<br />
its potential set the tone for the<br />
other lectures to follow.<br />
An exhibition with spread over 2,000<br />
m 2 of space and over 50 participating<br />
exhibitors and a conference with 12<br />
plenary lectures and 44 presentations<br />
in 2 parallel session threads were offered<br />
to the more than 700 <strong>de</strong>legates.<br />
The plenary talk of ‘Development<br />
of <strong>Alu</strong>minium in India: Science and<br />
Technology Roadmap’ by M. Goel of<br />
the governmental Department of Science<br />
and Technology gave some vital<br />
facts and figures: present annual<br />
production exceeds 1.2m tonnes, targeted<br />
production is 6m tonnes in the<br />
year 2020. The “need for <strong>de</strong>veloping<br />
an integrated technology roadmap for<br />
addressing energy efficiency concerns<br />
and promotion of environmentally<br />
friendly technologies” was highlighted.<br />
An in-<strong>de</strong>pth analysis of <strong>de</strong>mand<br />
and supply of various commodities<br />
and with particular focus on aluminium<br />
was presented by Paul Robinson<br />
of CRU UK. The challenges to the<br />
downstream industries in aluminium<br />
was brought out in <strong>de</strong>tail by Richard<br />
Brandtzaeg, Norsk Hydro. Conspicuous<br />
in other plenary sessions was the<br />
importance given to issues related to<br />
energy and environment; e<strong>special</strong>ly<br />
the carbon credit scheme presented<br />
by C. Cornier, a representative from<br />
the World Bank, on ‘Carbon finance<br />
business-Al sector in India’ attracted a<br />
lively discussion. Other plenary talks<br />
<strong>de</strong>alt with the current state of the art<br />
and trends in the aluminium industry.<br />
The exposition on automotive applications<br />
by K. H.von Zengen, EAA, was<br />
received with great interest.<br />
The papers presented in the parallel<br />
regular sessions covered the entire<br />
range of topics in the areas of production<br />
and recycling of aluminium,<br />
extrusion, dies, castings and forging.<br />
Over 60 percent of contributions by<br />
overseas speakers – notably those<br />
from the U. S. and Europe – in the<br />
sessions gave the conference a very<br />
international character.<br />
The organisers ma<strong>de</strong> an excellent<br />
job of the conference and fair by offering<br />
technical sessions and an exhibition<br />
of the highest standards and<br />
a forum for concerted interaction<br />
and personal networking to the participants.<br />
An extensive coverage by<br />
print and visual media ensured that<br />
a<strong>de</strong>quate attention was drawn to the<br />
programme not only within the participants,<br />
but the outsi<strong>de</strong> public in India<br />
as well. The forum was exten<strong>de</strong>d<br />
to the light cultural programmes and<br />
banquets. The facilities offered by the<br />
Hy<strong>de</strong>rabad International Convention<br />
Centre and the adjoining five star hotel<br />
ma<strong>de</strong> the conference memorable<br />
not only in terms of exchange of information<br />
and i<strong>de</strong>as concerning technical<br />
and economic issues but also in<br />
terms of convenience and comfort.<br />
As was mentioned in the closing<br />
session, those who missed Incal 2007<br />
will have to wait for the next Incal in<br />
2011. For <strong>de</strong>tails of Incal 2007 see<br />
http://www.aluminium-india.org/IN-<br />
CAL_07.pdf or contact aai@aluminium-india.org<br />
RWTH Update-Seminar<br />
Einführung in die Technologie <strong>de</strong>s <strong>Alu</strong>miniums<br />
11. bis 13. Februar 2008, Aachen<br />
Das aec – aluminium engineering<br />
center aachen, die RWTH International<br />
Aca<strong>de</strong>my GmbH und <strong>de</strong>r Gesamtverband<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie e. V.<br />
(GDA) veranstalten gemeinsam ein<br />
weiteres Mal das Fortbildungsseminar<br />
„Einführung in die Technologie<br />
<strong>de</strong>s <strong>Alu</strong>miniums“ in verschie<strong>de</strong>nen<br />
Instituten <strong>de</strong>r RWTH.<br />
Auch diesmal referieren namhafte<br />
Professoren <strong>de</strong>r RWTH Aachen über<br />
die Metallurgie, Herstellung, Verar-<br />
beitung und Anwendung von <strong>Alu</strong>minium.<br />
Ergänzt wer<strong>de</strong>n die Vorträge<br />
durch praktische Versuche. Im Laufe<br />
<strong>de</strong>r Veranstaltung wird, ausgehend<br />
von metallkundlichen Grundlagen,<br />
die gesamte Prozesskette durchlaufen,<br />
angefangen von <strong>de</strong>r Erzeugung<br />
von Primäraluminium über Gießprozesse,<br />
<strong>de</strong>r Umformung von <strong>Alu</strong>miniumbän<strong>de</strong>rn<br />
bis hin zur Beschichtung<br />
und Prüfung fertiger Bauteile.<br />
Die Teilnehmer erhalten sowohl<br />
M. Pandit, Kaiserslautern<br />
auf theoretischer als auch auf praktischer<br />
Ebene einen umfassen<strong>de</strong>n<br />
Überblick über die einzelnen Glie<strong>de</strong>r<br />
in <strong>de</strong>r Prozesskette. Bei erfolgreicher<br />
Teilnahme stellen die Veranstalter<br />
eine Teilnahmeurkun<strong>de</strong> aus.<br />
Das Seminar richtet sich in erster<br />
Linie an Naturwissenschaftler, Ingenieure<br />
und Techniker aus <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
und <strong>de</strong>r <strong>Alu</strong>minium<br />
verarbeiten<strong>de</strong>n Industrie ohne ausgeprägten<br />
werkstoffwissenschaftlichen<br />
102 ALUMINIUM · 1-2/2008
Hintergrund, eignet sich aber auch<br />
für Kaufleute z. B. aus Vertrieb und<br />
Einkauf, die sich einen technischen<br />
Überblick über <strong>de</strong>n Werkstoff <strong>Alu</strong>minium<br />
verschaffen wollen.<br />
Metals: Energy, Emissions and<br />
the Environment Conference<br />
11 to 12 February 2008, Brussels<br />
In the European metals industry, energy<br />
and climate change are high on<br />
the agenda. Both pose enormous challenges<br />
and threats, none more so than<br />
the risk of migration of European primary<br />
production. The conference will<br />
discuss key issues including: energy<br />
costs and impact on production and<br />
competitiveness, current and future<br />
regulation challenging the European<br />
metals industry, metals as innovative<br />
and sustainable materials, life-cycle<br />
<strong>de</strong>velopments, waste legislation and<br />
much more.<br />
Further information:<br />
Metal Bulletin Events<br />
Tel: +44 (0)20 7779 8989<br />
conferences@metalbulletin.com<br />
www.metalbulletin.com<br />
8. KBU – Kolloquium zu Wirtschaft<br />
und Umweltrecht<br />
28. bis 29. Februar 2008, Aachen<br />
Die gemeinsame Tagung <strong>de</strong>s Lehr- und<br />
Forschungsgebiets Berg- und Umweltrecht<br />
<strong>de</strong>r RWTH Aachen sowie <strong>de</strong>r<br />
GDMB Gesellschaft für Bergbau, Metallurgie,<br />
Rohstoff- und Umwelttechnik<br />
steht unter <strong>de</strong>r Thematik „10 Jahre<br />
Berg- und Umweltrecht: Habitatschutz<br />
– Mineralische Abfälle – Emissionshan<strong>de</strong>l“.<br />
Im Rahmen <strong>de</strong>r Entsorgung<br />
bergbaulicher Abfälle gilt es nach wie<br />
vor, die Richtlinie bergbauliche Abfälle<br />
umzusetzen. Der Emissionshan<strong>de</strong>l<br />
geht nunmehr in die zweite Run<strong>de</strong>,<br />
so dass sich die Auswirkungen auf die<br />
verschie<strong>de</strong>nen Branchen <strong>de</strong>utlicher<br />
zeigen. Hinzu kommt, dass scharfe<br />
Anfor<strong>de</strong>rungen aus <strong>de</strong>m Habitat- und<br />
Vogelschutz bergbaulichen Projekten<br />
Probleme bereiten o<strong>de</strong>r sie ganz blockieren.<br />
Hierzu wer<strong>de</strong>n auch Reformvorschläge<br />
präsentiert und bewertet.<br />
Weitere Infos:<br />
GDMB-Geschäftsstelle<br />
ALUMINIUM · 1-2/2008<br />
Weitere Informationen und Anmel<strong>de</strong>unterlagen:<br />
RWTH International Aca<strong>de</strong>my:<br />
Lydia Schnei<strong>de</strong>r<br />
Tel.: 0241 8020 708<br />
Tel: +49 (0)5323 9379 0<br />
eMail: gdmb@gdmb.<strong>de</strong><br />
www.gdmb.<strong>de</strong><br />
Ferrous & Non-ferrous Scrap Metal<br />
27 to 28 February 2008, Moscow<br />
The conference is <strong>de</strong>dicated to the<br />
issues of metal scrap recycling, price<br />
formation, and consumption in Russia<br />
and overseas. Direct networking<br />
and exchange of views will encourage<br />
the expansion of mutually beneficial<br />
cooperation between scrap metal recyclers<br />
and metallurgists. Participants<br />
are leading scrap metal collectors and<br />
recyclers, basic scrap metal consumers<br />
– steel works, tube plants, transport<br />
and logistics companies, scrap<br />
metal exporters of Russia, the CIS,<br />
and overseas. There will be arranged<br />
simultaneous translation into Russian<br />
and English.<br />
Further information:<br />
Rusmet.Ru Ltd.<br />
Tel: +7 495 980 0608<br />
lom@rusmet.ru<br />
www.lom.rusmet.ru<br />
14th Bauxite and <strong>Alu</strong>mina Seminar<br />
3 to 5 March 2008, Miami, USA<br />
Jointly organised by Industrial Minerals<br />
and Metal Bulletin, the 14th Bauxite<br />
and <strong>Alu</strong>mina seminar will provi<strong>de</strong> the<br />
forum in which to examine and <strong>de</strong>bate<br />
the key issues that will be influencing<br />
market dynamics for this important<br />
segment of the aluminium supply chain<br />
over the coming years. Key topics to be<br />
discussed are: alumina – latest global<br />
pressures and balances; bauxite – exploration<br />
and prospective; aluminium<br />
consolidation – impact and the implication<br />
for alumina supplies and tra<strong>de</strong><br />
flows; costs of alumina production –<br />
how to reduce the costs and maximize<br />
the production; logistics – problems<br />
and emerging trends; sustainability<br />
and environment issues – challenges<br />
ahead for the industry.<br />
EVENTS<br />
lydia.schnei<strong>de</strong>r@rwth-aca<strong>de</strong>my.com<br />
GDA:<br />
Wolfgang Heidrichw<br />
Telefon: 0211 4796 271<br />
wolfgang.heidrich@aluinfo.<strong>de</strong><br />
Further information:<br />
Metal Bulletin Events<br />
Tel: +44 (0)20 7779 8989<br />
conferences@metalbulletin.com<br />
www.metalbulletin.com<br />
LASYS – Messe für Systemlösungen<br />
in <strong>de</strong>r Laser-Materialbearbeitung<br />
4. bis 6. März 2008, Stuttgart<br />
Die weltweite Nachfrage nach Lasersystemen<br />
zur Materialbearbeitung<br />
steigt rapi<strong>de</strong> an und ist Ausdruck ständig<br />
erweiterter Einsatzbereiche <strong>de</strong>r<br />
Lasertechnik. Hier setzt die LASYS an:<br />
Sie zeigt Systeme und Verfahren für die<br />
ganze Palette <strong>de</strong>r Bearbeitungsformen<br />
– Schweißen, Schnei<strong>de</strong>n, Bohren, Löten,<br />
Beschriften u.v.m. – mit Laser.<br />
Damit ist sie Marktplatz und zugleich<br />
branchenübergreifen<strong>de</strong> Kommunikationsplattform.<br />
Die Messe wen<strong>de</strong>t<br />
sich an die Investitionsgüterindustrie,<br />
OEMs sowie Zulieferer. Einen Schwerpunkt<br />
<strong>de</strong>r Auftaktveranstaltung bil<strong>de</strong>n<br />
die Wirtschaftszweige, die <strong>de</strong>n Messestandort<br />
Stuttgart prominent prägen:<br />
Automobil- und -zulieferindustrie,<br />
Maschinen- und Anlagenbau, metallbearbeiten<strong>de</strong><br />
und -verarbeiten<strong>de</strong><br />
Industrie, Medizintechnik, Feinwerkund<br />
Präzisionstechnik.<br />
Weitere Infos:<br />
Lan<strong>de</strong>smesse Stuttgart GmbH<br />
Tel: +49 (0)711 2589 0<br />
info@messe-stuttgart.<strong>de</strong><br />
www.messe-stuttgart.<strong>de</strong><br />
TMS 2008<br />
9 to 13 March 2008, New Orleans, USA<br />
When materials scientists and engineers<br />
from 70 countries gather for the<br />
TMS 2008, the focus will be on sharing<br />
research and technology to find materials<br />
solutions to some of the world’s<br />
most pressing problems. More than<br />
2,000 papers will be presented by authors.<br />
Among the challenges they will<br />
address are: Resolving technology and<br />
techno-management issues for the pro-<br />
103
VERANSTALTUNGEN<br />
duction of aluminium, metal casting,<br />
steel, automotive and electronic materials;<br />
Stabilizing climate change and<br />
reducing greenhouse gas emissions;<br />
Optimizing energy utilization; Developing<br />
materials for high-performance<br />
applications; Achieving process improvement<br />
for a variety of materials<br />
un<strong>de</strong>r a variety of conditions; Preparing<br />
future materials scientists and engineers.<br />
These issues and others will<br />
be presented in 56 symposia covering<br />
the four major themes of light metals;<br />
extraction, processing, structure and<br />
properties; emerging materials; and<br />
materials and society.<br />
Further information:<br />
TMS Meetings Services<br />
724 776 9000<br />
mtgserv@tms.org<br />
www.tms.org<br />
3rd International Conference on<br />
High Speed Forming<br />
11 to 13 March 2008, Dortmund, GER<br />
Objectives and topics of the ICHSF<br />
2008 conference are: process technologies<br />
(electromagnetic, explosive<br />
and shock wave forming, combined<br />
processes), tools and equipment (tool<br />
<strong>de</strong>sign and manufacturing, machine<br />
<strong>de</strong>sign, pulsed power equipment), energy<br />
(process efficiency, emissions, life<br />
cycle analysis), materials and measurement<br />
techniques (material characteristics<br />
and behaviour, high speed testing<br />
methods, process monitoring, quality<br />
assurance), mo<strong>de</strong>lling and simulation<br />
(finite and boundary element method,<br />
physical mo<strong>de</strong>lling, analytical techniques,<br />
contact and impact mo<strong>de</strong>lling),<br />
industrial applications (e. g. automotive,<br />
aerospace, electrical industry,<br />
chemical industry).<br />
Further information:<br />
ICHSF 08<br />
Tel: +49 (0)231 755 - 6917, - 5238<br />
ichsf@iul.uni-dortmund.<strong>de</strong><br />
www.ichsf.iul.uni-dortmund.<strong>de</strong><br />
Euroguss und Internationaler<br />
Deutscher Druckgusstag<br />
11. bis 13. März 2008, Nürnberg<br />
Euroguss, die internationale Fachmesse<br />
für Druckgießtechnik ist auf Erfolgskurs.<br />
Sie hat nicht nur bei Fläche und<br />
Neuausstellern im Vergleich zur Veranstaltung<br />
2006 zugelegt, auch das Interesse<br />
<strong>de</strong>r internationalen Aussteller<br />
ist groß. Parallel zur Fachausstellung<br />
fin<strong>de</strong>t <strong>de</strong>r 8. Internationale Deutsche<br />
Druckgusstag statt, auf <strong>de</strong>m drei Tage<br />
lang hochkarätige Vorträge gehalten<br />
wer<strong>de</strong>n. Der Druckgusstag wird nun<br />
auch in <strong>de</strong>n Euroguss-freien Jahren<br />
in Nürnberg stattfin<strong>de</strong>n. Veranstalter<br />
ist <strong>de</strong>r i<strong>de</strong>elle Träger <strong>de</strong>r Messe, <strong>de</strong>r<br />
Fortbildung<br />
REACH – Das neue EU-Chemikalienrecht, 15. Februar 2008, Köln<br />
TÜV Nord Aka<strong>de</strong>mie, Tel: +49 (0)221 945352 0, akd-k@tuev-nord.<strong>de</strong>,<br />
www.tuevnordaka<strong>de</strong>mie.<strong>de</strong><br />
Schutztextilien, 19. Februar 2008, Altdorf<br />
Technische Aka<strong>de</strong>mie Wuppertal, Tel: +49 (0)202 7495 0, taw@taw.<strong>de</strong>,<br />
www.taw.<strong>de</strong><br />
Woche <strong>de</strong>r Oberflächentechnik an <strong>de</strong>r FH Hannover: Vorbehan<strong>de</strong>ln<br />
zur Verbesserung <strong>de</strong>r Haftung, 19. bis 20. Februar 2008, Hannover<br />
Weiterbildung und Technologietransfer, Tel: +49 (0)511 9296 1020,<br />
weiterbildung@fh-hannover.<strong>de</strong>, www.fh-hannover.<strong>de</strong><br />
Woche <strong>de</strong>r Oberflächentechnik an <strong>de</strong>r FH Hannover: Adhäsions-<br />
und Haftungsprüfung, 21. Februar 2008, Hannover<br />
Weiterbildung und Technologietransfer, Tel: +49 (0)511 9296 1020,<br />
weiterbildung@fh-hannover.<strong>de</strong>, www.fh-hannover.<strong>de</strong><br />
Produkthaftung – Risiken in Deutschland, Europa und USA,<br />
27. bis 28. Februar 2008, Regensburg<br />
OTTI Ostbayer. Technologie-Transfer-Institut, Tel: +49 (0)941 29688 26,<br />
hannelore.skobjin@otti.<strong>de</strong>, www.otti.<strong>de</strong><br />
Einführung in die Metallkun<strong>de</strong> für Ingenieure und Techniker,<br />
4. bis 7. März 2008, Darmstadt<br />
DGM Deutsche Gesellschaft für Materialkun<strong>de</strong> e.V., Tel: +49 (0)69 75306 757,<br />
np@dgm.<strong>de</strong>, www.dgm.<strong>de</strong><br />
Hightech-Klebstoffe und ihre Anwendungen, 10. bis 11. März 2008,<br />
Wuppertal<br />
Technische Aka<strong>de</strong>mie Wuppertal, Tel: +49 (0)202 7495 0, taw@taw.<strong>de</strong>,<br />
www.taw.<strong>de</strong><br />
Wirtschaftliche und technologische Aspekte endkonturnaher<br />
Fertigungsverfahren, 11. bis 12. März 2008, Düsseldorf<br />
VDI-Wissensforum GmbH, Tel: +49 (0)211 6214 201, wissensforum@vdi.<strong>de</strong>,<br />
www.vdi-wissensforum.<strong>de</strong><br />
Vom Mitarbeiter zur Führungskraft – Kompetenz und Souveränität<br />
von Anfang an, 11. bis 12. März 2008, Berlin<br />
TÜV Nord Aka<strong>de</strong>mie, Tel: +49 (0)30 201774 47, akd-b@tuev-nord.<strong>de</strong>,<br />
www.tuevnordaka<strong>de</strong>mie.<strong>de</strong><br />
Schweißgerechtes Konstruieren, 13. bis 14. März 2008, Köln<br />
VDI-Wissensforum GmbH, Tel: +49 (0)211 6214 201, wissensforum@vdi.<strong>de</strong>,<br />
www.vdi-wissensforum.<strong>de</strong><br />
Verband Deutscher Druckgießereien<br />
(VDD) in Kooperation mit <strong>de</strong>m Verein<br />
Deutscher Gießereifachleute (VDG).<br />
Weitere Infos:<br />
Nürnberg Messe GmbH<br />
Tel +49 (0)911 8606 0<br />
euroguss@nuernbergmesse.<strong>de</strong><br />
www.euroguss.<strong>de</strong><br />
104 ALUMINIUM · 1-2/2008
Lin, Q.; Peng, D.; Li, Y.; Lin, G.<br />
A study on the hot <strong>de</strong>formability of 2519 aluminum<br />
alloy at elevated temperatures<br />
Light Metal Age, Oktober 2007, S. 46-49<br />
The hot <strong>de</strong>formability of 2519 aluminum alloy un<strong>de</strong>r elevated<br />
temperatures was studied by the analysis of true stress-strain<br />
curves and observation of the <strong>de</strong>formed microstructures<br />
with an optical microscope (OM) and a transmission electron<br />
microscope (TEM). Compression tests were performed on a<br />
Gleeble-1500 thermal simulator at the <strong>de</strong>formation temperature<br />
range from 300°C to 500°C and at a strain rate range of<br />
0.05s -1 to 25s -1 . The experimental results showed that the flow<br />
stress of 2519 aluminum alloy increases with increasing strain<br />
and tends to be constant after a peak value at lower strain<br />
rates of ε
LITERATURSERVICE<br />
einen Bruchteil <strong>de</strong>r bei <strong>de</strong>r Primärgewinnung benötigten<br />
Energie aus. Beim Recycling haben jedoch Magnesiumlegierungen<br />
<strong>de</strong>n Nachteil, dass es bisher keine <strong>de</strong>finierten Sekundärlegierungen<br />
wie bei <strong>de</strong>n <strong>Alu</strong>miniumlegierungen gibt.<br />
Die Untersuchungen <strong>de</strong>s Gießverhaltens, <strong>de</strong>r mechanischen<br />
Eigenschaften und <strong>de</strong>r Korrosionseigenschaften <strong>de</strong>r neuen Sekundärlegierung<br />
AZC1231 zeigen, dass die bisher bestehen<strong>de</strong><br />
Lücke im Recycling von Magnesiumlegierungen mit dieser Legierung<br />
geschlossen wer<strong>de</strong>n konnte. Es ist nunmehr möglich,<br />
sowohl Altschrott als auch durch Kupfer und Nickel verunreinigte<br />
Magnesiumlieferungen durch einfaches Umschmelzen<br />
zu recyceln. Nachteilig wirkt sich die <strong>de</strong>utlich geringere<br />
Duktilität im Vergleich zu AZ91 aus. 16 Bild., 7 Tab., 10 Qu.<br />
ALUMINIUM 1/2 (2008) Recycling<br />
Karaaslan, A.; Lus, M.<br />
Rissvermeidung bei <strong>de</strong>r schmelzmetallurgischen Herstellung<br />
einer SiC-partikelverstärkten <strong>Alu</strong>miniumlegierung<br />
A6063<br />
MP Materials Testing 49 (2007) 11-12, S. 603-605<br />
Leichtmetall-Verbundwerkstoffe gewinnen aufgrund ihrer<br />
mechanisch-technologisch verbesserten Eigenschaften gegenüber<br />
<strong>de</strong>n unverstärkten Matrixwerkstoffen zunehmend<br />
an Be<strong>de</strong>utung. Die vorliegen<strong>de</strong> Arbeit befasst sich mit <strong>de</strong>r<br />
pulvermetallurgischen Herstellung eines mit Siliziumkarbid<br />
verstärkten <strong>Alu</strong>miniumpulvers. Ein beson<strong>de</strong>rs gutes Ergebnis<br />
wur<strong>de</strong> durch <strong>de</strong>n Zusatz von 12 Volumenprozent Siliziumkarbid<br />
beobachtet. Im Rahmen <strong>de</strong>r Untersuchungen wur<strong>de</strong>n<br />
neben <strong>de</strong>m Volumenanteil <strong>de</strong>r SiC-Teilchen auch die Gieß-<br />
und Formtemperatur variiert, um bei <strong>de</strong>r Herstellung von Verbundwerkstoffen<br />
die Verteilung <strong>de</strong>s SiC in <strong>de</strong>r Metallmatrix<br />
zu optimieren. 4 Bild., 2 Tab., 7 Qu.<br />
ALUMINIUM 1/2 (2008) Pulver<br />
Ji, J.; Jasnau, U.; Seyffarth, P.<br />
Gefügeverbesserung im Schweißgut beim Nd:<br />
YAG-Laserstrahl-MSG-Hybridschweißen von<br />
<strong>Alu</strong>miniumlegierungen<br />
Schweißen und Schnei<strong>de</strong>n 59 (2007) Heft 11, S. 608-612<br />
In <strong>de</strong>n bisherigen vier Teilen <strong>de</strong>r Veröffentlichungsreihe<br />
stan<strong>de</strong>n bei <strong>de</strong>r Qualitätssicherung von Nd:YAG-Laserstrahl-<br />
MSG-Hybridschweißverbindungen an <strong>Alu</strong>miniumlegierungen<br />
die Nahtformparameter, die Porenfreiheit und die Gewährleistung<br />
<strong>de</strong>r gefor<strong>de</strong>rten Einbrandtiefe im Zentrum. Da<br />
das Hybridschweißen eine verän<strong>de</strong>rte Wärmeeinbringung<br />
gegenüber <strong>de</strong>m reinen Laserschweißen mit sich bringt, ist die<br />
Frage <strong>de</strong>r Gefügebeeinflussung ebenfalls von Interesse für die<br />
Optimierung <strong>de</strong>r Nahteigenschaften. Insbeson<strong>de</strong>re ist zu untersuchen,<br />
inwieweit beim Laserstrahlhybridschweißen eine<br />
unzulässige Kornvergröberung auftritt. 7 Bild., 10 Qu.<br />
ALUMINIUM 1/2 (2008) Verbin<strong>de</strong>n<br />
Dragulin, D.; Franke, R.; Hoffmann, O.; Fischer, D.; Dragulin, M.<br />
<strong>Alu</strong>minium-Druckgusslegierung: Praktische Aspekte <strong>de</strong>s<br />
thermomechanischen Verhaltens <strong>de</strong>r AlSi10MnMg<br />
Druckgusspraxis 7/2007, S. 274-278<br />
Die Legierung AlSi10MnMg weist ausgesprochen gute mechanische<br />
Eigenschaften, insbeson<strong>de</strong>re Dehnung, im T7-Zustand<br />
auf und ist dadurch eine optimale Lösung für viele Strukturteile,<br />
die durch <strong>de</strong>n Druckgussprozess hergestellt wer<strong>de</strong>n<br />
können. Zu dieser Klasse gehört die Legierung Silafont-36 von<br />
<strong>Alu</strong>minium Rheinfel<strong>de</strong>n, die höhere Werte als eine Standard-<br />
AlSi10MnMg erreicht.<br />
Particular physical properties and certain thermo-physical<br />
processes have been examined for the predominantly utilised<br />
pressure die-casting alloy – AlSi10MnMg, as used in<br />
the car industry. As a result, an in-<strong>de</strong>pth study was carried out,<br />
which chiefly concentrated upon the thermo-elastic effect of<br />
this alloy, and upon its thermal effect in its zone of plasticity,<br />
as well as the elastic energy generated during <strong>de</strong>formation<br />
within this elasticity band. The study also entailed in-<strong>de</strong>pth<br />
analysis of its modulus with respect to tough show that the<br />
alloy – AlSi10MnMg – features an outstanding array of physical<br />
properties (e<strong>special</strong>ly with elongation in the T7 state) and<br />
therefore provi<strong>de</strong>s an optimum solution for many structural<br />
components, which can be produced by way of the pressure<br />
die-casting process. The alloy – Silafont-36 – produced by<br />
<strong>Alu</strong>minium Rheinfel<strong>de</strong>n, which attains even greater values<br />
than those provi<strong>de</strong>d by using standard AlSi10MnMg, belongs<br />
to this calssification. 8 Bild., 2 Tab., 2 Qu.<br />
ALUMINIUM 1/2 (2008) Werkstoffe, Metallkun<strong>de</strong><br />
Modulares Druckgusskonzept für leichte <strong>Alu</strong>minium-<br />
Zylin<strong>de</strong>rkurbelgehäuse<br />
Automotive Materials, 6/2007, S. 24-26<br />
Für die kostengünstige Herstellung von Zylin<strong>de</strong>rkurbelgehäusen<br />
aus <strong>Alu</strong>minium bietet sich <strong>de</strong>r Druckguss an. Das Verfahren<br />
beschränkt sich bisher auf die Open-Deck-Bauweise<br />
einschließlich <strong>de</strong>r damit bauartbedingt gegebenen geringeren<br />
Steifigkeit. Einen interessanten Lösungsansatz für „Downsizing“-Motoren<br />
präsentiert die KS <strong>Alu</strong>minium-Technologie AG<br />
mit ihrem hoch flexiblen, serienfähigen „modularen Druckgusskonzept“.<br />
Hierbei kompensieren einzelne Konzeptbausteine<br />
prinzipbedingte Nachteile <strong>de</strong>s herkömmlichen Druckgusses.<br />
Das Konzept ist generell geeignet, sehr große Mengen<br />
hochwertiger Al-Zylin<strong>de</strong>rkurbelgehäuse darzustellen.<br />
ALUMINIUM 1/2 (2008) Druckguss<br />
Zak, O.; Zak, H.; Tonn, B.<br />
Einsatz von rasch erstarrten Vorlegierungen zur Feinung<br />
<strong>de</strong>s Primärsiliziums übereutektischer AlSi17Cu4Mg-<br />
Legierung<br />
Druckgusspraxis 7/2007, S. 303-308<br />
Die im Rahmen dieser Arbeit gewonnenen neuen Erkenntnisse<br />
zeigen, dass <strong>de</strong>finierte Zusätze an Zirkonium ein<br />
enormes Potenzial für die Weiterentwicklung von AlSi-Standardlegierungen<br />
besitzen. In Versuchen mit <strong>de</strong>r technischen<br />
Legierung AlSi17Cu4Mg konnte die Größe <strong>de</strong>r Primärsiliziumkristalle<br />
von 40-50 μm (Stand <strong>de</strong>r Technik) auf 18 μm<br />
reduziert wer<strong>de</strong>n. Dieser Effekt wur<strong>de</strong> erreicht, in<strong>de</strong>m die<br />
feinen<strong>de</strong> Wirkung <strong>de</strong>s Phosphors durch gezielte Zugabe <strong>de</strong>s<br />
Zirkoniums, welches in Form einer schnell erstarrten Vorlegierung<br />
AlZr1,3 zum Einsatz kam, unterstützt wur<strong>de</strong>. Die Vorlegierung<br />
AlZr1,3 wur<strong>de</strong> an einer vertikalen Stranggießanlage<br />
mit einer Abkühlungsgeschwindigkeit von etwa 500 bis 600<br />
K/s hergestellt und erfor<strong>de</strong>rt dank feiner Gefügeausbildung<br />
und hohen Anteilen an in <strong>Alu</strong>minium-Matrix gelöstem Zirkonium<br />
beim Einsatz keine Überhitzung <strong>de</strong>r Schmelze und keine<br />
längere Haltezeiten. Durch kombinierte Zirkonium-und Phosphorzugabe<br />
konnte bei einem Phosphorgehalt von 100 ppm<br />
zusätzlich zur Feinung <strong>de</strong>s Primärsiliziums ein lamellares<br />
AlSi-Eutektikum und damit eine <strong>de</strong>utliche Verbesserung <strong>de</strong>r<br />
Festigkeitseigenschaften im Gusszustand um 35 Prozent erzielt<br />
wer<strong>de</strong>n, die bei <strong>de</strong>r Standardlegierung AlSi17Cu4Mg erst<br />
nach <strong>de</strong>r Wärmebehandlung T6 erreicht wer<strong>de</strong>n können.<br />
New possibilities in influencing the micro-structure of hypereutectic<br />
AlSi17Cu4Mg, used for pistons and engine blocks,<br />
are presented in this report, so that this material can meet the<br />
increased <strong>de</strong>mands imposed by the automobile industry. The<br />
basic concept for the examinations, which were conducted<br />
for this purpose, focused upon the fact that the smelts are to<br />
be treated by means of rapidly solidifying AISi14- and AlZr1<br />
har<strong>de</strong>ning alloys, and that the effect of these har<strong>de</strong>ning alloys<br />
upon the primary silicon phase nee<strong>de</strong>d to be examined<br />
individually as well as jointly in conjunction with phospho-<br />
106 ALUMINIUM · 1-2/2008
us. It shows that the har<strong>de</strong>ning alloys that were utilised, the<br />
microstructures of which <strong>de</strong>viate consi<strong>de</strong>rably from those of<br />
the bulk alloy materials, effect a notable refinement of the<br />
primary silicon in the AlSi17Cu4Mg alloy. It was discovered<br />
that upon adding the rapidly solidifying AlZr1,3 alloy, together<br />
with phosphorus, a particularly marked effect was able to be<br />
accomplished upon the primary silicon, and as a consequence<br />
of this, has proven to have had an effect upon the physical<br />
properties of the AlSi17Cu4Mg alloy, even in the state when it<br />
is cast. The same comparable level of physical properties can<br />
only be attained for “standard” alloy after T6 heat treatment<br />
has been carried out. 7 ill., 3 tables., 19 sources.<br />
ALUMINIUM 1/2 (2008) Werkstoffe<br />
Blauel, J. G.; Pfeiffer, W.; Varfolomeyev, I.; Veneziano, C.<br />
Bruchmechanische Bewertung von rissbehafteten<br />
Schweißkonstruktionen mit Eigenspannungen<br />
MP Materials Testing 49 (2007) 11-12, S. 577-587<br />
Die Anwendung bruchmechanischer Konzepte bei <strong>de</strong>r<br />
Festigkeitsbewertung von Schweißkonstruktionen erlaubt<br />
prinzipiell neben <strong>de</strong>n werkstoffspezifischen Effekten auch<br />
die Wirkung von Eigenspannungen auf vorhan<strong>de</strong>ne Imperfektionen<br />
quantitativ zu erfassen. Mögliche Vorgehensweisen<br />
bei <strong>de</strong>n dafür durchzuführen<strong>de</strong>n Einzelschritten – Eigenspannungsermittlung,<br />
Beanspruchungsanalyse, Kennwertermittlung<br />
und Versagensbewertung – wer<strong>de</strong>n beschrieben und<br />
anhand von Beispielen <strong>de</strong>monstriert. 22 Bild., 23 Qu.<br />
ALUMINIUM 1/2 (2008) Verbin<strong>de</strong>n<br />
Sölter, J.; Reucher, G.<br />
Werkstoffeinfluss auf die Spanbildung bei hohen<br />
Schnittgeschwindigkeiten<br />
MM Maschinenmarkt 43/2007, S. 46-51<br />
Die Spanbildung und die Abhängigkeit <strong>de</strong>r Prozesskräfte von<br />
<strong>de</strong>r Schnittgeschwindigkeit wer<strong>de</strong>n stark durch <strong>de</strong>n Werkstoff<br />
und <strong>de</strong>n Wärmebehandlungszustand <strong>de</strong>s Werkstücks<br />
beeinflusst. Außer thermischen und mechanischen Werkstoffeigenschaften<br />
entschei<strong>de</strong>n die Mikrostruktur und die<br />
chemische Zusammensetzung <strong>de</strong>s Werkstoffs, ob eine Spansegmentierung<br />
bei hohen Schnittgeschwindigkeiten einsetzt.<br />
5 Bild, 7 Qu.<br />
ALUMINIUM 1/2 (2008) Umformen<br />
E<strong>de</strong>r, Chr.<br />
Thixocasting für komplexe Geometrien – Lösungen aus<br />
einem Guss<br />
Automotive Materials, 6/2007, S. 36-37<br />
Aufgrund <strong>de</strong>s steigen<strong>de</strong>n Kostendrucks streben Automobil-<br />
und Nutzfahrzeughersteller Lösungen an, bei <strong>de</strong>nen sich komplexe<br />
Geometrien in Net-Shape-Qualität ohne nachfolgen<strong>de</strong><br />
mechanische Bearbeitung realisieren lassen. Hierbei bietet<br />
sich das Thixocasting <strong>de</strong>r österreichischen SAG Thixalloy<br />
Components an. Kriterien für Thixocasting-Anwendungen<br />
sind: keine Teile mit geringen Qualitätsanfor<strong>de</strong>rungen, große<br />
Unterschie<strong>de</strong> in <strong>de</strong>n Wanddicken realisierbar, hohe Komplexität<br />
<strong>de</strong>r Konstruktion und Integration von Funktionen,<br />
ALUMINIUM · 1-2/2008<br />
LITERATURE SERVICE<br />
Druckdichtigkeit durch porenarme Qualität, thermische<br />
Behandlungen – hohe Schweißeignung, Wärmebehandlung,<br />
hohe Anfor<strong>de</strong>rungen an die Oberfläche, Thixocasting kann<br />
beson<strong>de</strong>rs Prozesse wie mechanische Bearbeitung, Schmie<strong>de</strong>n,<br />
Feinguss, Kokillenguss, Vakuum-Druckguss substituieren,<br />
Ersatz von gefügten Blech- und Strangpressteilen durch<br />
Integration.<br />
ALUMINIUM 1/2 (2008) Formguss<br />
Schleich, R.; Papaioanu, A.; Liewald, M.<br />
Karosserieblech sicher biegen<br />
Blech, Rohre, Profile 11/2007, S. 22-23<br />
Mechanische Werkstoffkennwerte sind in <strong>de</strong>r Umformtechnik<br />
ein etabliertes Mittel zur Qualitätssicherung. Für biegedominierte<br />
Verfahren scheinen die konventionellen Kennwerte<br />
unzureichend. Am Institut für Umformtechnik (IFU )<br />
in Stuttgart wird <strong>de</strong>shalb ein Prüfverfahren entwickelt, das<br />
mit einer falzprozessnahen Kinematik und <strong>de</strong>n relevanten<br />
Spannungszustän<strong>de</strong>n operiert. 4 Bild.<br />
ALUMINIUM 1/2 (2008) Umformen<br />
<strong>Alu</strong>minium Oxid Sta<strong>de</strong> – Auch nach 35 Jahren<br />
eine <strong>de</strong>r effizientesten Oxidfabriken in <strong>de</strong>r Welt<br />
<strong>Alu</strong>minium 83 (2007) 12, S. 26-31<br />
Seit 1973 verarbeitet die <strong>Alu</strong>minium Oxid Sta<strong>de</strong> GmbH Bauxit<br />
zu <strong>Alu</strong>miniumoxid. Ursprünglich auf die Produktion von Oxid<br />
für die <strong>Alu</strong>miniumelektrolyse ausgelegt, hat sich AOS längst<br />
auf die Herstellung von chemischem Oxid und von Hydroxidprodukten<br />
fokussiert. Noch immer zählt AOS zu <strong>de</strong>n technisch<br />
und energetisch effizientesten Oxidfabriken in <strong>de</strong>r Welt. 2007<br />
wird erstmals die Produktion von 1 Mio. Tonnen erreicht. Von<br />
<strong>de</strong>n sechs in Europa produzieren<strong>de</strong>n Oxidfabriken ist AOS bei<br />
chemischen Produkten die Nummer 1. Der Beitrag geht auf die<br />
anlagentechnischen Beson<strong>de</strong>rheiten ein, mit <strong>de</strong>nen sich AOS<br />
vom Wettbewerb abhebt. Artikel dt./engl. 4 Fotos.<br />
ALUMINIUM 1/2 (2008) Gewinnung<br />
Trommer, G.<br />
Mo<strong>de</strong>rne Verfahren zum Schweißen von <strong>Alu</strong>minium -<br />
Viele Wege führen zum Ziel<br />
<strong>Alu</strong>minium 83 (2007) 12, S. 34-39<br />
Das Fügeverfahren Schweißen spielt für <strong>de</strong>n Konstruktionswerkstoff<br />
<strong>Alu</strong>minium eine dominieren<strong>de</strong> Rolle. Von beson<strong>de</strong>rer<br />
Be<strong>de</strong>utung sind Anwendungen <strong>de</strong>s Maschinen- und<br />
Apparatebaus, im Verkehrswesen sowie im Bauwesen. Beim<br />
Schweißen von <strong>Alu</strong>minium sind, im Vergleich zu Stahl, jedoch<br />
einige Beson<strong>de</strong>rheiten zu beachten. Sie hängen primär mit<br />
<strong>de</strong>n Werkstoffeigenschaften <strong>de</strong>s Leichtmetalls zusammen. Der<br />
Beitrag zeigt Zusammenhänge und Lösungen für Schweißverbindungen<br />
auf. Die Spannbreite <strong>de</strong>r Ausführungen reicht vom<br />
Elektro<strong>de</strong>n-Handschweißen über das WIG-, Orbital-, Plasma-,<br />
MIG-, CMT-, Laser-MSG-Lichtbogen-Schweißen bis hin zum<br />
Wi<strong>de</strong>rstands-Punktschweißen „DeltaSpot“. 6 Fotos.<br />
ALUMINIUM 1/2 (2008) Schweißen<br />
Für Schrifttum zum Thema „<strong>Alu</strong>minium“ ist <strong>de</strong>r Gesamtverband <strong>de</strong>r <strong>Alu</strong>miniumindustrie e.V. (GDA)<br />
<strong>de</strong>r kompetente Ansprechpartner. Die hier referierten Beiträge repräsentieren lediglich einen Ausschnitt<br />
aus <strong>de</strong>m umfassen<strong>de</strong>n aktuellen Bestand <strong>de</strong>r GDA-Bibliothek.<br />
Die von <strong>de</strong>r <strong>Alu</strong>minium-Zentrale seit <strong>de</strong>n dreißiger Jahren kontinuierlich aufgebaute Fach-Bibliothek<br />
wird duch <strong>de</strong>n GDA weitergeführt, ausgebaut und auf die neuen Medien umgestellt. Sie steht allen<br />
Interessenten offen.<br />
Ansprechpartner ist Dr. Karsten Hein, E-Mail: karsten.hein@aluinfo.<strong>de</strong><br />
107
PATENTE<br />
Patentblatt November 2007<br />
Al-Si-Lotlegierungen und Ihre Verwendung<br />
für das Hartlöten von <strong>Alu</strong>minium<br />
und <strong>Alu</strong>minium/Stahl-Fügungen.<br />
Umicore AG & Co. KG, 63457 Hanau,<br />
DE. (B23K 35/28, EPA 1842619, EP-AT:<br />
10.04.2007)<br />
Neue Al-Cu-Li-Mg-Ag-Mn-Zr-Legierung<br />
für Bauanwendungen, die hohe Festigkeit<br />
und hohe Bruchzähigkeit erfor<strong>de</strong>rn.<br />
Alcan Rolled Products Ravenswood LLC,<br />
Ravenswood, W.Va., US. (C22C 21/12,<br />
EPA 1641953, EP-AT: 26.05.2004)<br />
Dünne Bän<strong>de</strong>r o<strong>de</strong>r Bleche aus einer Al-<br />
Fe-Si-Legierung. Novelis,Inc., Toronto,<br />
Ontario, CA. (C22C 1/00, PS 60 2004 005<br />
045, EP 1644545, EP-AT: 19.07.2004)<br />
Verfahren zum Tiefziehen von Teilen<br />
aus Al-Mg-Legierungen. Alcan Rhenalu,<br />
Paris, FR. (B21D 22/20, EP 1601478, EP-<br />
AT: 24.02.2004)<br />
Grobblech o<strong>de</strong>r stranggepresstes Teil<br />
aus <strong>Alu</strong>minium-Magnesium-Legierung.<br />
Aleris <strong>Alu</strong>minium Koblenz GmbH, 56070<br />
Koblenz, DE. (C22C 21/06, PS 697 03 441,<br />
EP 0892858, EP-AT: 27.03.1997)<br />
Kohlenwasserstoffumwandlungsverfahren<br />
unter Verwendung einer <strong>Alu</strong>minium<br />
und ein zweiwertiges Metall enthalten<strong>de</strong>n<br />
Katalysatorzusammensetzung.<br />
Albemarle Netherlands B.V., Amersfoort,<br />
NL. (B01J 21/16, ) EPA 1838436, EP-AT:<br />
19.11.2005)<br />
Verfahren zum Auswechseln einer Ano<strong>de</strong><br />
in einer Zelle zur elektrolytischen<br />
Herstellung von <strong>Alu</strong>minium mit Einstellung<br />
<strong>de</strong>r Position <strong>de</strong>r Ano<strong>de</strong> und Wartungsvorrichtung<br />
dafür. E.C.L., Ronchin,<br />
FR. (C25C 3/06, EPA 1838901, EP-AT:<br />
12.10.2005)<br />
Verfahren und Vorrichtung zum Vorbereiten<br />
eines Bauteils aus oberflächlich<br />
oxidieren<strong>de</strong>m Metall, insbeson<strong>de</strong>re aus<br />
<strong>Alu</strong>minium, zum Schweißen o<strong>de</strong>r Kleben.<br />
SLE Electronic GmbH, 94481 Grafenau,<br />
DE. (B08B 3/00, PS 10 2006 009<br />
993, AT: 03.03.2006)<br />
Vorrichtung und Verfahren zur Sicherung<br />
von als Paket gelagerten <strong>Alu</strong>minium-Stranggussprodukten,<br />
so genannten<br />
Masseln, zu Transportzwecken. Signo<strong>de</strong><br />
System GmbH, 46535 Dinslaken,<br />
DE. (B65D 85/62, PS 10 2006 038 996,<br />
AT: 21.08.2006)<br />
Gummibauteil mit Metallkomponente<br />
auf Basis von <strong>Alu</strong>minium und Verfahren<br />
zum Herstellen <strong>de</strong>sselben. Tokai<br />
Rubber Industries, Ltd., Komaki, Aichi,<br />
JP. (C23C 30/00, OS 10 2007 020 030,<br />
AT: 27.04.2007)<br />
<strong>Alu</strong>minium-Gusslegierung. EADS<br />
Deutschland GmbH, 85521 Ottobrunn,<br />
DE; <strong>Alu</strong>minium Rheinfel<strong>de</strong>n GmbH,<br />
79618 Rheinfel<strong>de</strong>n, DE. (C22C 21/06, PS<br />
103 52 932, AT: 11.11.2003)<br />
In einem <strong>Alu</strong>minium-Gussteil einzugießen<strong>de</strong>r<br />
Grauguss-Rohling und entsprechen<strong>de</strong>s<br />
Gussverfahren. Audi AG, 85057<br />
Ingolstadt, DE. (F02F 1/00, OS 198 36<br />
706, AT: 13.08.1998)<br />
Behan<strong>de</strong>ln von Abstandhaltern in gestapelten<br />
<strong>Alu</strong>minium-Blöcken. Alcoa Inc.,<br />
Pittsburgh, Pa., US. (C21D 1/70, PS 601<br />
23 737, EP 1215289, EP-AT: 11.12.2001)<br />
Verfahren zum Hartlöten einer <strong>Alu</strong>minium-Magnesium-Legierung<br />
mit einem<br />
Kalium-Fluorozinkat enthalten<strong>de</strong>n<br />
Flussmittel. Denso Corp., Kariya, Aichi,<br />
JP; Sumitomo Light Metal Industries,<br />
Ltd., Tokio/Tokyo, JP. (B23K 1/00, PS<br />
60 2004 004 428, EP 1466691, EP-AT:<br />
31.03.2004)<br />
Randspannungsentlastung von Grobblech<br />
aus <strong>Alu</strong>minium. Alcan Rhenalu,<br />
Paris, FR. (C22F 1/00, PS 603 12 373, EP<br />
1567685, EP-AT: 04.12.2003)<br />
Wärmebehandlungsverfahren für Blech<br />
aus <strong>Alu</strong>minium-Legierung. Novelis, Inc.,<br />
Toronto, Ontario, CA. (C22F 1/05, PS 695<br />
20 007, EP 0805879, EP-AT: 05.09.1995)<br />
Hochfestes Blech aus Al-Zn-Cu-Mg-Legierung<br />
mit geringen inneren Spannungen.<br />
Alcan Rhenalu, Paris, FR. (C22F 1/053,<br />
EPA 1838891, EP-AT: 09.12.2005)<br />
Endloskapillarrohr in <strong>Alu</strong>miniumlegierung,<br />
Drosselventil mit diesem Endloskapillarrohr<br />
in <strong>Alu</strong>miniumlegierung und<br />
<strong>Alu</strong>miniumlegierung. Aro Tubi Trafilerie<br />
S.p.A., Milano, IT; C.R. S.r.l., Moniga Del<br />
Garda, IT. (F25B 41/06, EPA 1840487,<br />
EP-AT: 31.03.2006)<br />
6xxx-<strong>Alu</strong>miniumlegierung. Comalco<br />
<strong>Alu</strong>minium Ltd., Melbourne, Victoria,<br />
AU. (C22C 21/02, EPA 1840234, EP-AT:<br />
04.07.1997)<br />
Platte aus einer <strong>Alu</strong>miniumlegierung<br />
und Herstellungsverfahren dafür. Kabushiki<br />
Kaisha Kobe Seiko Sho, Kobe,<br />
Hyogo, JP. (C22C 21/06, EPA 1842935,<br />
EP-AT: 13.01.2006)<br />
Lötmaterial für <strong>Alu</strong>miniumlegierung.<br />
Aleris <strong>Alu</strong>minum Koblenz GmbH, 56070<br />
Koblenz, DE. (B23K 35/28, EPA 1843872,<br />
EP-AT: 10.01.2006)<br />
Abschreckunempfindliche <strong>Alu</strong>miniumlegierung<br />
sowie Verfahren zum Herstellen<br />
eines Halbzeuges aus dieser Legierung.<br />
Otto Fuchs KG, 58540 Meinerzhagen,<br />
DE. (C22C 21/10, EP 1 683 882, EP-AT:<br />
21.11.2005)<br />
Wärmebehandlung von Druckgussstücken<br />
aus <strong>Alu</strong>miniumlegierung. Commonwealth<br />
Scientific and Industrial Research<br />
Organisation, Campbell, AU. (C22F 1/04,<br />
EPA 1844174, EP-AT: 19.12.2005)<br />
<strong>Alu</strong>miniumlegierung für Gussteil. Dr.Ing.<br />
h.c. F. Porsche AG, 70435 Stuttgart, DE.<br />
(C22C 21/02, EPA 1840233, EP-AT:<br />
12.12.2006)<br />
Anodisieren<strong>de</strong> <strong>Alu</strong>miniumlegierung.<br />
Short Brothers PLC, Belfast, Nordirland,<br />
GB. (C25D 11/12, EPA 1836331, EP-AT:<br />
10.01.2006)<br />
Partikelverstärkte Magnesium- o<strong>de</strong>r<br />
<strong>Alu</strong>miniumlegierung. Bayerische Motoren<br />
Werke AG, 80809 München, DE.<br />
(C22C 49/04, OS 10 2006 023 041, AT:<br />
17.05.2006)<br />
<strong>Alu</strong>miniumlegierung, Verbindungs- und<br />
Halteeinrichtung für Glaskonstruktionsvorhaben.<br />
Ting, Jen-Chieh, Kaohsiung<br />
City, TW. (E04B 1/38, GM 20 2007 009<br />
426, AT: 05.07.2007)<br />
Warmfeste <strong>Alu</strong>miniumlegierung. <strong>Alu</strong>minium<br />
Rheinfel<strong>de</strong>n GmbH, 79618 Rheinfel<strong>de</strong>n,<br />
DE. (C22C 21/08, EP 1 757 709,<br />
EP-AT: 28.02.2006)<br />
Druckgusserzeugnis aus <strong>Alu</strong>miniumlegierung.<br />
Corus <strong>Alu</strong>minium Voer<strong>de</strong><br />
GmbH, 46562 Voer<strong>de</strong>, DE; Corus <strong>Alu</strong>minium<br />
Walzprodukte GmbH, 56070 Koblenz,<br />
DE. (C22C 21/06, PS 601 26 529,<br />
EP 1138794, EP-AT: 15.03.2001)<br />
<strong>Alu</strong>miniumlegierung geeignet für Bleche<br />
und ein Verfahren zu <strong>de</strong>ren Herstellung.<br />
Furukawa-Sky <strong>Alu</strong>minum Corp., Tokio/<br />
Tokyo, JP; Honda Giken Kogyo K.K., Tokyo,<br />
JP. (C22C 21/00, PS 602 15 579, EP<br />
1260600, EP-AT: 15.05.2002)<br />
Wärmetauscher. Showa Denko K.K., Minato-ku,<br />
Tokyo, JP. (F28F 9/02, WO 2006<br />
059783, WO-AT: 30.11.2005)<br />
Vorrichtung zur Fertigung von aus<br />
Leichtmetall gefertigten Holmen eines<br />
Rahmens und/o<strong>de</strong>r eines Flügels eines<br />
Fensters. Aug. Winkhaus GmbH & Co.<br />
KG, 48291 Telgte, DE. (B21D 53/74, EPA<br />
1839770, EP-AT: 22.12.2006)<br />
Kühlkokille zum Vergießen von Leichtmetall-Gusswerkstoffen<br />
und Verwendung<br />
einer solchen Kokille sowie eines<br />
Gusseisenwerkstoffs. Hydro <strong>Alu</strong>minium<br />
Deutschland GmbH, 51149 Köln,<br />
DE. (B22C 9706, EPA 1841554, EP-AT:<br />
27.01.2006)<br />
Verfahren zum Gießen von Bauteilen aus<br />
Leichtmetall nach <strong>de</strong>m Kippgießprinzip.<br />
Rautenbach-Guß Wernigero<strong>de</strong> GmbH,<br />
38855 Wernigero<strong>de</strong>, DE. (B22D 23/00,<br />
EP 1 742 752, EP-AT: 30.03.2005)<br />
108 ALUMINIUM · 1-2/2008
Verbundmaterial aus Leichtmetall und<br />
mit Kohlenstofffasern verstärktem<br />
Kunststoff. Toray Industries, Inc., Tokio/<br />
Tokyo, JP. (B32B 15/08, PS 698 36 259,<br />
EP 0938969, EP-AT: 20.08.1998)<br />
Anordnung zur Bildung einer Kreuzverbindung<br />
zwischen einem Längspfosten<br />
und einem Querpfosten bei einem Fenster<br />
o<strong>de</strong>r einer Türe aus Kunststoff o<strong>de</strong>r<br />
Leichtmetall. PHI Technik für Fenster<br />
und Türen GmbH, 91459 Markt Erlbach,<br />
DE. (E06B 3/964, GM 299 14 966, AT:<br />
26.08.1999)<br />
Magnesiumlegierungen für die Wasserstoffspeicherung.<br />
The University of<br />
Queensland, Santa Lucia, Queensland,<br />
AU. (C22C 23/00, EPA EP 1838887, EP-<br />
AT: 02.12.2005)<br />
Hochfeste Legierung auf <strong>Alu</strong>miniumbasis<br />
und ein daraus hergestelltes Produkt.<br />
Fe<strong>de</strong>ralnoe Gosudarstvatelsky Institut<br />
Unitarnoe Predpriyatie “Vserossiisky<br />
Nauchno-Issledovatelsky Institut Aviatsionnykh<br />
Materialov”, Moskau/Moscow,<br />
RU; Otkrytoe Aktsionernoe Obschestvo<br />
“Samarsky Metallurgichesky Zavod”, Samara,<br />
RU. (C22C 21/10, PS 601 20 987,<br />
EP 1306455, EP-AT: 25.07.2001)<br />
Aus min<strong>de</strong>stens zwei vorgegossenen<br />
Abschnitten zusammengesetztes Bauteil<br />
und Verfahren zu seiner Herstellung.<br />
Hydro <strong>Alu</strong>minium Mandl&Berger GmbH,<br />
Linz, AT. (B22D 19/04, OS 10 2005 059<br />
309, AT: 09.12.2005)<br />
Verbundprofil mit einem Tragkörper aus<br />
Leichtmetallwerkstoff sowie einem Profilband<br />
und Verfahren zum Herstellen<br />
<strong>de</strong>s Verbundprofils. Alcan Technology &<br />
Management Ltd., Neuhausen am Rheinfall,<br />
CH. (B60M 1/30 und B21K 9/00, OS<br />
10 2005 063 436 und PS 10 2005 004 547<br />
und EPA 1843866, AT: 31.01.2005 und<br />
EP-AT: 20.12.2005)<br />
Wärmetauscher. Showa Denko K.K., Tokio/Tokyo,<br />
JP. (F28D 1/053, WO 2006<br />
070923, WO-AT: 27.12.2005)<br />
Verpackungsbeutel mit Umverpackung.<br />
Alcan Technology & Management<br />
Ltd., Neuhausen am Rheinfall,<br />
CH. (B65D 33/02, EPA 1714892, EP-AT:<br />
24.11.2005)<br />
Profilelement zum Befestigen einer<br />
Stoßstange an Längsträgern eines Fahrzeuges<br />
sowie Verfahren dazu. Alcan<br />
Technology & Management AG, Neuhausen<br />
am Rheinfall, CH. (B60R 19/34, OS 10<br />
2006 019 654, AT: 25.04.2006<br />
Schlauchförmiges Glied mit einem aus<br />
mehreren Metalldrähten o<strong>de</strong>r -Röhren<br />
bestehen<strong>de</strong>n Umfang. Norsk Hydro<br />
ASA, Oslo, NO. (F16L 11/14, EP 1 563<br />
215, EP-AT: 27.10.2003)<br />
ALUMINIUM · 1-2/2008<br />
Profil aus einem Leichtmetallwerkstoff<br />
mit an diesem verlaufen<strong>de</strong>n Rohrelementen.<br />
Alcan Technology & Management<br />
AG, Neuhausen am Rheinfall,<br />
CH.(E04D 3/30, GM 20 2007 008 488,<br />
AT: 13.06.2007)<br />
Verfahren zur Herstellung von grobkörnigem<br />
<strong>Alu</strong>miniumhydroxyd. Alcan<br />
Technology & Management AG, Neuhausen<br />
am Rheinfall, CH. (C01F 7/14, PS 698<br />
36 962, EP 0997435, EP-AT: 28.10.1998)<br />
Inerte Cermet-Ano<strong>de</strong> zur Verwendung<br />
in <strong>de</strong>r elektrolytischen Herstellung von<br />
Metallen. Alcoa Inc., Pittsburgh, Pa., US.<br />
(C25C 3/12, PS 600 33 837, EP 1226287,<br />
EP-AT: 27.10.2000)<br />
Gießform, Vorrichtung und Verfahren<br />
zum Vergießen von Metallschmelze.<br />
Hydro <strong>Alu</strong>minium <strong>Alu</strong>cast GmbH, 66763<br />
Dillingen, DE. (B22C 9/08, PS 10 2005<br />
010 838, AT: 07.03.2005)<br />
Wärmetauscherprofil. Erbslöh <strong>Alu</strong>minium<br />
GmbH, 42553 Velbert, DE. (F28F<br />
1/02, EPA 1840494, EP-AT: 23.03.2007)<br />
Verfahren und Stellgliedvorrichtung.<br />
Norsk Hydro ASA, Oslo, NO. (E21B 43/32,<br />
EP 1 718 842, EP-AT: 11.02.2005)<br />
Funktionale Direktbeschichtung einer<br />
<strong>Alu</strong>miniumfolie. Hydro <strong>Alu</strong>minium<br />
Deutschland GmbH, 51149 Köln, DE.<br />
(B21C 47/26, EPA 1837091, EP-AT:<br />
09.03.2007)<br />
Wasserkühlsystem für eine Stranggießvorrichtung.<br />
Norsk Hydro ASA, Oslo/<br />
Osló, NO. (B22D 11/049, PS 601 24 031,<br />
EP 1157765, EP-AT: 14.05.2001)<br />
Flexibles Rohr o<strong>de</strong>r flexibler Schlauch.<br />
Alcan Deutschland GmbH, 37075 Göttingen,<br />
DE. (F16L 59/153, PS 502 08 527, EP<br />
1286102, EP-AT: 14.08.2002)<br />
<strong>Alu</strong>miniummaterial für eine Elektro<strong>de</strong><br />
eines elektrolytischen Kon<strong>de</strong>nsators,<br />
Verfahren zur Herstellung von Elektro<strong>de</strong>nmaterial<br />
für einen elektrolytischen<br />
Kon<strong>de</strong>nsator, Ano<strong>de</strong>nmaterial für einen<br />
elektrolytischen <strong>Alu</strong>miniumkon<strong>de</strong>nsator<br />
und elektrolytischer <strong>Alu</strong>miniumkon<strong>de</strong>nsator.<br />
Showa Denko K.K., Tokio/Tokyo,<br />
JP. (C22C 21/00, EPA 1841892, EP-AT:<br />
21.12.2005)<br />
Einrichtung und Verfahren zur Sammlung<br />
<strong>de</strong>r Abflüsse einer Elektrolysezelle.<br />
<strong>Alu</strong>minium Pechiney, Voreppe,<br />
FR. (C25C 3/22, EPA 1845175, EP-AT:<br />
11.04.2006)<br />
Schaltungsanordnung zum Steuern<br />
eines Krustenbrechers. VAW <strong>Alu</strong>minium-Technologie<br />
GmbH, 53117 Bonn,<br />
DE. (C25C 3/20, GM 299 10 803, AT:<br />
21.06.1999)<br />
PATENTE<br />
Verfahren zur Herstellung von <strong>Alu</strong>miniumverbundwerkstoff.<br />
<strong>Alu</strong>minium Core<br />
Technology Co., Ltd., Tokyo, JP; Nippon<br />
Light Metal Co. Ltd., Tokio/Tokyo,<br />
JP. (B22F 3/24, EPA 1837103, EP-AT:<br />
28.12.2005)<br />
Dachreling sowie Verfahren zur Herstellung<br />
einer solchen Dachreling. WKW<br />
Erbslöh Automotive GmbH, 42349 Wuppertal,<br />
DE. (B60R 9/04, OS 10 2006 025<br />
933, AT: 10.05.2006)<br />
Magnesiumlegierung und dazugehöriges<br />
Herstellungsverfahren. Biotronik VI<br />
Patent AG, Baar, CH. (C22C 23/04, EPA<br />
1840235, EP-AT: 22.03.2007)<br />
Verfahren zum Gießen eines Artikels.<br />
Mahle Powertrain Ltd., St. James, Northampton,<br />
GB. (B22C 9/02, EPA 1841553,<br />
EP-AT: 08.12.2005)<br />
Innere Rohrprüfvorrichtung und Verfahren.<br />
Norsk Elektro Optikk AS, Skarer,<br />
NO. (F16L 55/26, PS 603 11 977, EP<br />
1497585, EP-AT: 04.04.2003)<br />
<strong>Alu</strong>miniumlagerlegierungsteil. Daido<br />
Metal Co. Ltd., Nagoya, Aichi, JP. (C22C<br />
21/00, PS 101 35 895, AT: 24.07.2001)<br />
Patentblatt Dezember 2007<br />
Verfahren zum MIG Schweißen von Al-<br />
Legierungen mit Ar/He/O 2-Schutzgas.<br />
L‘Air Liqui<strong>de</strong> Société Anonyme pour<br />
l‘Etu<strong>de</strong> et l‘Exploitation <strong>de</strong>s Procédés<br />
Georges Clau<strong>de</strong>, Paris, Ce<strong>de</strong>x, FR. (B23K<br />
9/16, EP 1 166 940, EP-AT: 11.06.2001<br />
Druckgießen von <strong>Alu</strong>minium. Commonwealth<br />
Scientific and Industrial Research<br />
Organisation, Campbell, AU: (B22D<br />
17/20, PS 601 28 114, EP 1320434, EP-<br />
AT: 24.08.2001)<br />
Verfahren zum Aufbringen einer Beschichtung<br />
auf überlappten Oberflächen<br />
von Bauelementen aus <strong>Alu</strong>minium-Legierung<br />
sowie <strong>de</strong>rart beschichtete überlappte<br />
Oberflächen. McDonnell Douglas<br />
Corp., Seal Beach, Calif., US. (C22F 1/04,<br />
PS 699 35 480, EP 0985737, EP-AT:<br />
25.08.1999)<br />
<strong>Alu</strong>minium-Zink-Magnesium-Scandium-<br />
Legierungen und Herstellungsverfahren<br />
dafür. Langan, Timothy, Catonsville, Md.,<br />
US. (C22C 21/10, EPA 1848835, EP-AT:<br />
01.02.2006)<br />
Neue Fe-Al-Legierung und Herstellungsverfahren<br />
dafür. Okanda, Yoshihira, Nishinomiya,<br />
JP. (C21D 9/46, EPA 1847624,<br />
EP-AT: 10.02.2006)<br />
Verfahren unter Verwendung von ausgewählten<br />
Kohlen zur Reaktion �<br />
109
PATENTE<br />
mit Al 2 O- und Al-Dämpfen bei <strong>de</strong>r carbothermischen<br />
Produktion von <strong>Alu</strong>minium.<br />
Alcoa Inc., Pittsburgh, Pa., US; Elkem<br />
AS, Oslo, NO; Carnegie Mellon University,<br />
Pittsburgh, Pa., US. (C22B 21/02, EP<br />
1 689 895, EP-AT: 02.12.2004)<br />
Verfahren zum Diffusionsfügen von Magnesium/<strong>Alu</strong>minium-Bauteilen.<br />
General<br />
Motors Corp., Detroit, Mich., US. (B23K<br />
35/28, PS 602 16 369, EP 1273385, EP-<br />
AT: 08.05.2002)<br />
Verbindung von Profilen, insbeson<strong>de</strong>re<br />
<strong>Alu</strong>minium-Strangpressprofilen im Fahrzeugbau.<br />
Siemens AG, 80333 München,<br />
DE. (F16B 5/00, EPA 1688626, EP-AT:<br />
09.01.2006)<br />
Verfahren zum Versiegeln von mit Phosphorsäure<br />
anodisiertem <strong>Alu</strong>minium. The<br />
United States of America as represented<br />
by the Secretary of the Navy, Lilj Patuxent<br />
River, Md., US. (C23C 22/05, EPA<br />
1853750, EP-AT: 14.11.2005)<br />
Verbundblech aus <strong>Alu</strong>minium. Aleris<br />
<strong>Alu</strong>minium Duffel BVBA, Duffel, BE.<br />
(B32B 15/01, EPA 1852251, EP-AT:<br />
02.05.2006)<br />
Metallisierung integrierter Schaltungen<br />
unter Verwendung einer Titan-<strong>Alu</strong>minium-Legierung.<br />
Micron Technology, Inc.,<br />
Boise, Id., US. (H01L 23/532, OS 101 52<br />
913, AT: 26.10.2001)<br />
Verbundwerkstoff aus einer hochfesten<br />
<strong>Alu</strong>miniumlegierung. Visteon Global<br />
Technologies, Inc., Dearborn, Mich., US.<br />
(C22C 21/04, PS 10 2004 033 457, AT:<br />
05.07.2004)<br />
Titan-<strong>Alu</strong>minium-Mischoxidpulver. Evonik<br />
Degussa GmbH, 40474 Düsseldorf,<br />
DE. (C01G 25/02, OS 10 2004 061 702<br />
und OS 10 2004 061 703 und OS 10<br />
2004 062 104, AT: 22.12.2004 und AT:<br />
23.12.2004)<br />
Stabilisiertes <strong>Alu</strong>minium-Zirkon-Mischoxidpulver.<br />
Evonik Degussa GmbH,<br />
40474 Düsseldorf, DE. (C01G 1/02, OS<br />
10 2005 040 156, AT: 25.08.2005)<br />
Profilsystem, Halter und Verfahren zur<br />
Befestigung für und Austausch von SG-<br />
Verglasung (Structural Glazing) von <strong>de</strong>r<br />
Rauminnenseite für <strong>Alu</strong>minium-Glas-<br />
Fassa<strong>de</strong>n und an<strong>de</strong>re SG-Metall-Glas-<br />
Fassa<strong>de</strong>n. inotec Engineering GmbH,<br />
74532 Ilshofen, DE. (E04B 2/96, OS 10<br />
2006 026 283, AT: 02.06.2006)<br />
Durchsichtige <strong>Alu</strong>minium-Titanoxid-Beschichtung<br />
und / o<strong>de</strong>r <strong>Alu</strong>miniumoxid-<br />
Beschichtung mit einer Rutilstruktur.<br />
Philips Intellectual Property & Standards<br />
GmbH, 20099 Hamburg, DE. (C03C<br />
17/24, PS 60 2004 005 571, EP 1590305,<br />
EP-AT: 21.01.2004)<br />
Drehtrommelofen zum Umschmelzen<br />
von <strong>Alu</strong>minium. Metallhüttenwerke<br />
Bruch GmbH, 44145 Dortmund, DE.<br />
(F27B 7/20, GM 20 2004 004 478, AT:<br />
19.03.2004)<br />
<strong>Alu</strong>miniumhaltige Fällungskieselsäure<br />
mit einstellbarem BET/CTAB-Verhältnis.<br />
Evonik Degussa GmbH, 40474 Düsseldorf,<br />
DE. (C01B 33/193, PS 503 02 199,<br />
EP 1513768, EP-AT: 07.06.2003)<br />
Vorrichtung und Drehsicherung von<br />
Dosenen<strong>de</strong>n in einem Downstaker und<br />
entsprechen<strong>de</strong>s Verfahren. Alcoa Inc.,<br />
Pittsburgh, Pa., US. (B65D 1/00, PS 603<br />
13 345, EP 1545987, EP-AT: 05.08.2003)<br />
Vorrichtung zum Entwässern <strong>de</strong>r Rahmenstöße<br />
einer Vorhangfassa<strong>de</strong>. Norsk<br />
Hydro ASA, Oslo, NO. (E04B 2/88, EPA<br />
1849928, EP-AT: 13.02.2007)<br />
Oberflächenbehandlungsmittel und Verfahren<br />
zum Entfernen <strong>de</strong>r beim Ätzen<br />
von Druckgussteilen aus <strong>Alu</strong>minium<br />
anfallen<strong>de</strong>n Si-Komponente und reduzierten<br />
Metallsalze. Jeonyoung Co., Ltd.,<br />
Ansan, Kyounggi, KR. (C11D 7/18, PS 602<br />
16 291, EP 1421164, EP-AT: 25.07.2002)<br />
Verfahren zum Sintern von <strong>Alu</strong>minium-<br />
und <strong>Alu</strong>miniumlegierungsteilen. Ex One<br />
Corp., Irwin, Pa., US. (C22C 1/04, EP 1<br />
694 875, EP-AT: 01.12.2003)<br />
<strong>Alu</strong>minium-Elektrolytkon<strong>de</strong>nsator und<br />
Herstellungsverfahren. Matsushita Electric<br />
Industrial Co., Ltd., Kadoma, Osaka,<br />
JP. (H01G 9/008, PS 699 34 063, EP<br />
0986078, EP-AT: 03.09.1999)<br />
Verfahren zur Herstellung von anorganisch<br />
gebun<strong>de</strong>nen Formen und Kernen<br />
für Gießereizwecke, insbeson<strong>de</strong>re für<br />
das Leichtmetall-Gießen. Otto-von-Guericke-Universität<br />
Mag<strong>de</strong>burg, 39106<br />
Mag<strong>de</strong>burg, DE. (B22C 1/18, OS 10 2006<br />
026 796, AT: 07.06.2006)<br />
Verpackungsbeutel. Alcan Technology &<br />
Management Ltd., Neuhausen am Rheinfall,<br />
CH. (B65D 33/02, EPA 1854732, EP-<br />
AT: 12.05.2006)<br />
Verfahren zur Herstellung von Verpackungsbeuteln.<br />
Alcan Technology & Management<br />
Ltd., Neuhausen am Rheinfall,<br />
CH. (B65D 75/50, EP 1 547 935, EP-AT:<br />
23.12.2003)<br />
Verfahren zum Abtrennen von Abfallschichten<br />
von plattierten Bän<strong>de</strong>rn durch<br />
Walzplattieren. Alcan Rhenalu, Paris, FR.<br />
(B21B 47/04, PS 60 2004 003 371, EP<br />
1628786, EP-AT: 01.06.2004)<br />
Vorrichtung und Verfahren zum Aufbringen<br />
von Sprühpumpen und <strong>de</strong>rgleichen<br />
auf Behälter und zum Verschließen<br />
<strong>de</strong>rselben. Alcoa Deutschland GmbH,<br />
67547 Worms, DE. (B65B 7/28, EP 1 761<br />
434, EP-AT: 20.06.2005)<br />
Profilverbindung, insbeson<strong>de</strong>re für <strong>Alu</strong>minium-Leichtbau.<br />
Philippi, Gerd, 66793<br />
Saarwellingen, DE. (F16B 7/00, GM 20<br />
2004 013 726, AT: 03.09.2004)<br />
Vakuumhartlötverfahren für <strong>Alu</strong>minium.<br />
Denso Corp., Kariya, Aichi, JP. (F27B<br />
5/05, PS 4404263, AT:10.02.1994)<br />
Verfahren zum Biegen eines bahnförmigen<br />
Stehfalzprofilbleches und Einrichtung<br />
zur Durchführung dieses Verfahrens.<br />
Corus Bausysteme GmbH, 56070<br />
Koblenz, DE. (B21D 7/08, EP 1 631 399,<br />
EP-AT: 07.05.2004)<br />
Verfahren zur Herstellung eines halbfesten<br />
Thixogießmaterials. Honda Giken<br />
Kogyo K.K., Tokyo, JP. (C21D 1/32, PS 697<br />
37 048, EP 1460138, EP-AT: 02.09.1997)<br />
Verfahren zur Herstellung eines Behälters<br />
aus <strong>Alu</strong>miniumblechen. Hydro <strong>Alu</strong>minium<br />
Deutschland GmbH, 51149 Köln,<br />
DE. (B21D 51/18, OS 10 2006 026 828,<br />
AT: 07.06.2006)<br />
Verfahren und Vorrichtung zur Herstellung<br />
eines Sandwichpaneels und<br />
nach diesem Verfahren hergestelltes<br />
Sandwichpaneel. Corus Technology BV,<br />
IJmui<strong>de</strong>n, NL. (E04 2/292, EP 1 233 114,<br />
EP-AT: 08.02.2002)<br />
Vorrichtung zum Fügen von min<strong>de</strong>stens<br />
zwei Bauteilen aus artverschie<strong>de</strong>nen<br />
Werkstoffen mit einem mit min<strong>de</strong>stens<br />
einem als Schnei<strong>de</strong> ausgebil<strong>de</strong>ten Formelement<br />
aufweisen<strong>de</strong>n Stift. Hydro <strong>Alu</strong>minium<br />
Deutschland GmbH, 51149 Köln,<br />
DE. (B23K 20/12, EPA 1849552, EP-AT:<br />
27.04.2006)<br />
Fortsetzung <strong>de</strong>r Dezember-Auswertung in<br />
<strong>de</strong>r nächsten Ausgabe <strong>de</strong>r ALUMINIUM.<br />
ALUMINIUM veröffentlicht unter<br />
dieser Rubrik regelmäßig einen Überblick<br />
über wichtige, <strong>de</strong>n Werkstoff<br />
<strong>Alu</strong>minium betreffen<strong>de</strong> Patente. Die<br />
ausführlichen Patentblätter und auch<br />
weiterführen<strong>de</strong> Informationen dazu<br />
stehen <strong>de</strong>r Redaktion nicht zur Verfügung.<br />
Interessenten können diese<br />
beziehen o<strong>de</strong>r einsehen bei <strong>de</strong>r<br />
Mittel<strong>de</strong>utschen Informations-, Patent-,<br />
Online-Service GmbH (mipo),<br />
Julius-Ebeling-Str. 6,<br />
D-06112 Halle an <strong>de</strong>r Saale,<br />
Tel. 0345/29398-0<br />
Fax 0345/29398-40,<br />
www.mipo.<strong>de</strong><br />
Die Gesellschaft bietet darüber hinaus<br />
weitere „Patent“-Dienstleistungen an.<br />
110 ALUMINIUM · 1-2/2008
International Journal for Industry, Research and Application<br />
How do your products and services come to appear every month in the<br />
list of supply sources, on the internet – www.<strong>Alu</strong>-<strong>web</strong>.<strong>de</strong> – and in the<br />
annual list of supply sources published by ALUMINIUM ?<br />
� Please mark the main group relevant to you<br />
❑ Smelting technology ❑ Rolling technology<br />
❑ Extrusion ❑ Foundry<br />
� Indicate the sub-group and/or key word<br />
(if necessary, ask us for the list of key words)<br />
_______________________ _______________________<br />
_______________________ _______________________<br />
_______________________ _______________________<br />
� Enter your text, not forgetting your on-line address:<br />
Line 1: ............................................................................................................................................<br />
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Line 3: ............................................................................................................................................<br />
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(Maximum 35 characters per line, including spaces.<br />
Price per line for each issue EUR 5,00 + VAT – minimum or<strong>de</strong>r 10 issues = 1 year.<br />
Logos are calculated according to the lines they occupy: 1 line = 2 mm).<br />
_______________________________________________________________<br />
Place/Date Company stamp / Signature<br />
� … and send this form to us by fax or post:<br />
Fax number For information Giesel Verlag GmbH, ALUMINIUM<br />
+49-511/7304-157 Tel.: -142 Rehkamp 3, D-30916 Isernhagen<br />
We will gladly send you a quotation!
LIEFERVERZEICHNIS<br />
1<br />
Smelting technology<br />
Hüttentechnik<br />
1.1 Raw materials<br />
1.2 Storage facilities for smelting<br />
1.3 Ano<strong>de</strong> production<br />
1.4 Ano<strong>de</strong> rodding<br />
1.5 Casthouse (foundry)<br />
1.6 Casting machines<br />
1.7 Current supply<br />
1.8 Electrolysis cell (pot)<br />
1.9 Potroom<br />
1.10 Laboratory<br />
1.11 Emptying the catho<strong>de</strong> shell<br />
1.12 Catho<strong>de</strong> repair shop<br />
1.13 Second-hand plant<br />
1.14 <strong>Alu</strong>minium alloys<br />
1.15 Storage and transport<br />
1.1 Raw Materials<br />
Rohstoffe<br />
� Raw Materials<br />
Rohstoffe<br />
TRIMET ALUMINIUM AG<br />
Nie<strong>de</strong>rlassung Düsseldorf<br />
Heinrichstr. 155<br />
D-40239 Düsseldorf<br />
Tel.: +49 (0) 211 / 96180-0<br />
Fax: +49 (0) 211 / 96180-60<br />
Internet: www.trimet.<strong>de</strong><br />
1.2 Storage facilities for<br />
smelting<br />
Lagermöglichkeiten<br />
in <strong>de</strong>r Hütte<br />
Möller Materials Handling GmbH<br />
Ha<strong>de</strong>rslebener Straße 7<br />
D-25421 Pinneberg<br />
Telefon: 04101 788-0<br />
Telefax: 04101 788-115<br />
E-Mail: info@moeller-mh.com<br />
Internet: www.moeller-mh.com<br />
Kontakt: Herr Dipl.-Ing. Timo Letz<br />
Outotec GmbH<br />
Phone: +49 (0) 2203 / 9921-0<br />
www.outotec.com<br />
� Conveying systems bulk materials<br />
För<strong>de</strong>ranlagen für Schüttgüter<br />
(Hüttenaluminiumherstellung)<br />
Möller Materials Handling GmbH<br />
Internet: www.moeller-mh.com<br />
see Storage facilities for smelting 1.2<br />
1.1 Rohstoffe<br />
1.2 Lagermöglichkeiten in <strong>de</strong>r Hütte<br />
1.3 Ano<strong>de</strong>nherstellung<br />
1.4 Ano<strong>de</strong>nschlägerei<br />
1.5 Gießerei<br />
1.6 Gießmaschinen<br />
1.7 Stromversorgung<br />
1.8 Elektrolyseofen<br />
1.9 Elektrolysehalle<br />
1.10 Labor<br />
1.11 Ofenwannenentleeren<br />
1.12 Katho<strong>de</strong>nreparaturwerkstatt<br />
1.13 Gebrauchtanlagen<br />
1.14 <strong>Alu</strong>miniumlegierungen<br />
1.15 Lager und Transport<br />
� Unloading/Loading equipment<br />
Entla<strong>de</strong>-/Bela<strong>de</strong>einrichtungen<br />
Möller Materials Handling GmbH<br />
Internet: www.moeller-mh.com<br />
see Storage facilities for smelting 1.2<br />
1.3 Ano<strong>de</strong> production<br />
Ano<strong>de</strong>nherstellung<br />
Outotec GmbH<br />
see Storage facilities for smelting 1.2<br />
� Auto firing systems<br />
Automatische Feuerungssysteme<br />
RIEDHAMMER GmbH<br />
D-90332 Nürnberg<br />
E-Mail: goe<strong>de</strong>.frank@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
� Exhaust gas treatment<br />
Abgasbehandlung<br />
ALSTOM Norway AS<br />
Tel. +47 22 12 70 00<br />
Internet: www.environment.power.alstom.com<br />
� Hydraulic presses for prebaked<br />
ano<strong>de</strong>s / Hydraulische Pressen zur<br />
Herstellung von Ano<strong>de</strong>n<br />
LAEIS GmbH<br />
Am Scheerleck 7, L-6868 Wecker, Luxembourg<br />
Phone: +352 27612 0<br />
Fax: +352 27612 109<br />
E-Mail: info@laeis-gmbh.com<br />
Internet: www.laeis-gmbh.com<br />
Contact: Dr. Alfred Kaiser<br />
� Open top and closed<br />
type baking furnaces<br />
Offene und geschlossene Ringöfen<br />
RIEDHAMMER GmbH<br />
D-90332 Nürnberg<br />
E-Mail: goe<strong>de</strong>.frank@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
1.4 Ano<strong>de</strong> rodding<br />
Ano<strong>de</strong>nanschlägerei<br />
Outotec GmbH<br />
see Storage facilities for smelting 1.2<br />
� Removal of bath residues from<br />
the surface of spent ano<strong>de</strong>s<br />
Entfernen <strong>de</strong>r Badreste von <strong>de</strong>r Ober -<br />
fläche <strong>de</strong>r verbrauchten Ano<strong>de</strong>n<br />
GLAMA Maschinenbau GmbH<br />
Hornstraße 19<br />
D-45964 Gladbeck<br />
Telefon 02043 / 9738-0<br />
Telefax 02043 / 9738-50<br />
� Transport of finished ano<strong>de</strong><br />
elements to the pot room<br />
Transport <strong>de</strong>r fertigen Ano<strong>de</strong>nelemente<br />
in Elektrolysehalle<br />
Hovestr. 10 . D-48431 Rheine<br />
Telefon + 49 (0) 59 7158-0<br />
Fax + 49 (0) 59 7158-209<br />
E-Mail info@windhoff.<strong>de</strong><br />
Internet www.windhoff.<strong>de</strong><br />
112 ALUMINIUM · 1-2/2008
1.5 Casthouse (foundry)<br />
Gießerei<br />
HERTWICH ENGINEERING GmbH<br />
Maschinen und Industrieanlagen<br />
Weinbergerstraße 6, A-5280 Braunau am Inn<br />
Phone +437722/806-0<br />
Fax +437722/806-122<br />
E-Mail: info@hertwich.com<br />
Internet: www.hertwich.com<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
Konstantinstraße 1a<br />
D 41238 Mönchengladbach<br />
Telefon +49 (02166) 987990<br />
Telefax +49 (02166) 987996<br />
E-Mail: info@inotherm-gmbh.<strong>de</strong><br />
Internet: www.inotherm-gmbh.<strong>de</strong><br />
OTTO JUNKER GmbH<br />
SIGNODE® SYSTEM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
Stopinc AG<br />
Bösch 83 a<br />
CH-6331 Hünenberg<br />
Tel. +41/41-785 75 00<br />
Fax +41/41-785 75 01<br />
E-Mail: interstop@stopinc.ch<br />
Internet: www.stopinc.ch<br />
� Bone ash / Knochenasche<br />
IMPERIAL-OEL-IMPORT<br />
Bergstraße 11, D 20095 Hamburg<br />
Tel. 040/338533-0, Fax: 040/338533-85<br />
E-Mail: info@imperial-oel-import.<strong>de</strong><br />
� Clay / Toner<strong>de</strong><br />
TRIMET ALUMINIUM AG<br />
Nie<strong>de</strong>rlassung Düsseldorf<br />
Heinrichstr. 155<br />
D-40239 Düsseldorf<br />
Tel.: +49 (0) 211 / 96180-0<br />
Fax: +49 (0) 211 / 96180-60<br />
Internet: www.trimet.<strong>de</strong><br />
ALUMINIUM · 1-2/2008<br />
see Extrusion 2<br />
� Degassing, filtration and<br />
grain refinement<br />
Entgasung, Filtern, Kornfeinung<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
� Dross skimming of liquid metal<br />
Abkrätzen <strong>de</strong>s Flüssigmetalls<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Furnace charging with<br />
molten metal<br />
Ofenbeschickung mit Flüssigmetall<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Melting/holding/casting furnaces<br />
Schmelz-/Halte- und Gießöfen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
Sistem Teknik Ltd. Sti.<br />
DES San. Sit. 102 SOK No: 6/8<br />
Y.Dudullu, TR-34775 Istanbul/Turkey<br />
Tel.: +90 216 420 86 24<br />
Fax: +90 216 420 23 22<br />
E-Mail: info@sistemteknik.com<br />
Internet: www.sistemteknik.com<br />
� Metal treatment in the<br />
holding furnace<br />
Metallbehandlung in Halteöfen<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Transfer to the casting furnace<br />
Überführung in Gießofen<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
LIEFERVERZEICHNIS<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
Stadtseestraße 12<br />
D-74189 Weinsberg<br />
Tel. +49 (0) 7134 / 52-220<br />
Fax +49 (0) 7134 / 52-222<br />
E-Mail intralogistik@vollert.<strong>de</strong><br />
Internet www.vollert.<strong>de</strong><br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Transport of liquid metal<br />
to the casthouse<br />
Transport von Flüssigmetall<br />
in Gießereien<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
MARX GmbH & Co. KG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Treatment of casthouse<br />
off gases<br />
Behandlung <strong>de</strong>r Gießereiabgase<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
1.6 Casting machines<br />
Gießmaschinen<br />
OTTO JUNKER GmbH<br />
� Pig casting machines<br />
(sow casters)<br />
Masselgießmaschine (Sowcaster)<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
see Equipment and accessories 2.11<br />
Outotec GmbH<br />
see Extrusion 2<br />
see Storage facilities for smelting 1.2<br />
113
LIEFERVERZEICHNIS<br />
� Rolling and extrusion ingot<br />
and T-bars<br />
Formatgießerei (Walzbarren o<strong>de</strong>r<br />
Pressbolzen o<strong>de</strong>r T-Barren)<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Vertical semi-continuous DC<br />
casting / Vertikales Stranggießen<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
see Equipment and accessories 2.11<br />
� Horizontal continuous casting<br />
Horizontales Stranggießen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Scales / Waagen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Sawing / Sägen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Heat treatment of extrusion<br />
ingot (homogenisation)<br />
Formatebehandlung (homogenisieren)<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
see Billet Heating Furnaces 1.5<br />
1.8 Electrolysis cell (pot)<br />
Elektrolyseofen<br />
� Insulating bricks / Isoliersteine<br />
Promat GmbH – Techn. Wärmedämmung<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
� Pot feeding systems<br />
Beschickungseinrichtungen<br />
für Elektrolysezellen<br />
Möller Materials Handling GmbH<br />
Internet: www.moeller-mh.com<br />
see Storage facilities for smelting 1.2<br />
1.9 Potroom<br />
Elektrolysehalle<br />
T.T. Tomorrow Technology S.p.A.<br />
Via <strong>de</strong>ll’Artigianato 18<br />
Due Carrare, Padova 35020, Italy<br />
Telefon +39 049 912 8800<br />
Telefax +39 049 912 8888<br />
E-Mail: gmagarotto@tomorrowtechnology.it<br />
Contact: Giovanni Magarotto<br />
� Ano<strong>de</strong> changing machine<br />
Ano<strong>de</strong>nwechselmaschine<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Tapping vehicles<br />
Schöpffahrzeuge<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Crustbreakers / Krustenbrecher<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Dry absorption units for<br />
electrolysis exhaust gases<br />
Trockenabsorptionsanlage für<br />
Elektrolyseofenabgase<br />
ALSTOM Norway AS<br />
Tel. +47 22 12 70 00<br />
Internet: www.environment.power.alstom.com<br />
� Ano<strong>de</strong> transport equipment<br />
Ano<strong>de</strong>n Transporteinrichtungen<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� HF Measurementtechnology<br />
HF Messtechnik<br />
OPSIS AB<br />
Box 244, S-24402 Furulund, Schwe<strong>de</strong>n<br />
Tel. +46 (0) 46-72 25 00, Fax -72 25 01<br />
E-Mail: info@opsis.se<br />
Internet: www.opsis.se<br />
1.15 Storage and transport<br />
Lager und Transport<br />
HUBTEX Maschinenbau GmbH & Co. KG<br />
Werner-von-Siemens-Str. 8<br />
D-36041 Fulda<br />
Tel. +49 (0) 661 / 83 82-0<br />
Fax +49 (0) 661 / 83 82-120<br />
E-Mail: info@hubtex.com<br />
Internet: www.hubtex.com<br />
114 ALUMINIUM · 1-2/2008
Extrusion<br />
2 Strangpressen<br />
2.1 Extrusion billet preparation<br />
2.2 Extrusion equipment<br />
2.3 Section handling<br />
2.4 Heat treatment<br />
2.5 Measurement and control equipment<br />
2.6 Die preparation and care<br />
2.7 Second-hand extrusion plant<br />
2.8 Consultancy, expert opinion<br />
2.9 Surface finishing of sections<br />
2.10 Machining of sections<br />
2.11 Equipment and accessories<br />
2.12 Services<br />
www.otto-junker-group.com<br />
Jägerhausstr. 22<br />
D – 52152 Simmerath<br />
Telefon: +49 2473 601 0<br />
Telefax: +49 2473 601 600<br />
E-Mail: info@otto-junker.<strong>de</strong><br />
Kontakt: Herr Teichert / Flat Equipment<br />
Herr Dr. Menzler / Extru<strong>de</strong>d Equipment<br />
Herr Donsbach / Foundry Equipment<br />
Kingsbury Road<br />
Curdworth<br />
UK - SUTTON COLDFIELD B76 9EE<br />
Telefon: +44 1675 470551<br />
Telefax: +44 1675 470645<br />
E-Mail: info@otto-junker.co.uk<br />
Kontakt: Mr. Beard<br />
IUT Industriell Ugnsteknik AB<br />
Industrivägen 2<br />
43892 Härryda, Swe<strong>de</strong>n<br />
Telefon: +46 (0) 301 31510<br />
Telefax: +46 (0) 301 30479<br />
E-Mail: office@iut.se<br />
Kontakt: Mr. Berge<br />
2.1 Extrusion billet<br />
preparation<br />
Pressbolzenbereitstellung<br />
SIGNODE® SYSTEM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
ALUMINIUM · 1-2/2008<br />
2.1 Pressbolzenbereitstellung<br />
2.2 Strangpresseinrichtungen<br />
2.3 Profilhandling<br />
2.4 Wärmebehandlung<br />
2.5 Mess- und Regeleinrichtungen<br />
2.6 Werkzeugbereitstellung und -pflege<br />
2.7 Gebrauchte Strangpressanlagen<br />
2.8 Beratung, Gutachten<br />
2.9 Oberflächenveredlung von Profilen<br />
2.10 Profilbearbeitung<br />
2.11 Ausrüstungen und Hilfsmittel<br />
2.12 Dienstleistungen<br />
� Billet heating furnaces<br />
Öfen zur Bolzenerwärmung<br />
Am großen Teich 16+27<br />
D-58640 Iserlohn<br />
Tel. +49 (0) 2371 / 4346-0<br />
Fax +49 (0) 2371 / 4346-43<br />
E-Mail: verkauf@ias-gmbh.<strong>de</strong><br />
Internet: www.ias-gmbh.<strong>de</strong><br />
MARX GmbH & Co. KG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
Sistem Teknik Ltd. Sti.<br />
DES San. Sit. 102 SOK No: 6/8<br />
Y.Dudullu, TR-34775 Istanbul/Turkey<br />
Tel.: +90 216 420 86 24<br />
Fax: +90 216 420 23 22<br />
E-Mail: info@sistemteknik.com<br />
Internet: www.sistemteknik.com<br />
� Billet heating units<br />
Anlagen zur Bolzenerwärmung<br />
OTTO JUNKER GmbH<br />
� Billet transport and<br />
storage equipment<br />
Bolzen Transport- und<br />
Lagereinrichtungen<br />
OTTO JUNKER GmbH<br />
see Extrusion 2<br />
see Extrusion 2<br />
LIEFERVERZEICHNIS<br />
� Hot shears / Warmscheren<br />
OTTO JUNKER GmbH<br />
see Extrusion 2<br />
2.2 Extrusion equipment<br />
Strangpresseinrichtungen<br />
Oilgear Towler GmbH<br />
Im Gotthelf 8<br />
D 65795 Hattersheim<br />
Tel. +49 (0) 6145 3770<br />
Fax +49 (0) 6145 30770<br />
E-Mail: info@oilgear.<strong>de</strong><br />
Internet: www.oilgear.<strong>de</strong><br />
SMS Meer GmbH<br />
Schloemann Extrusion<br />
Ohlerkirchweg 66<br />
D-41069 Mönchengladbach<br />
Tel. +49 (0) 2161 / 3500<br />
Fax +49 (0) 2161 / 3501667<br />
E-Mail: info@sms-meer.com<br />
Internet: www.sms-meer.com<br />
� Containers / Rezipienten<br />
KIND & CO., EDELSTAHLWERK, KG<br />
Bielsteiner Straße 128-130<br />
D-51674 Wiehl<br />
Telefon: +49 (0) 2262 / 84 0<br />
Telefax: +49 (0) 2262 / 84 175<br />
E-Mail: info@kind-co.<strong>de</strong><br />
Internet: www.kind-co.<strong>de</strong><br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
115
LIEFERVERZEICHNIS<br />
� Extrusion / Strangpressen<br />
OTTO JUNKER GmbH<br />
� Press control systems<br />
Pressensteuersysteme<br />
Oilgear Towler GmbH<br />
see Extrusion Equipment 2.2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Temperature measurement<br />
Temperaturmessung<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Heating and control<br />
equipment for intelligent<br />
billet containers<br />
Heizungs- und Kontrollausrüstung<br />
für intelligente Blockaufnehmer<br />
MARX GmbH & Co. KG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
2.3 Section handling<br />
Profilhandling<br />
SIGNODE® SYSTEM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
� Homogenising furnaces<br />
Homogenisieröfen<br />
see Extrusion 2 OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
� Packaging equipment<br />
Verpackungseinrichtungen<br />
H+H HERRMANN + HIEBER GMBH<br />
För<strong>de</strong>rsysteme für Paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
� Puller equipment<br />
Ausziehvorrichtungen/Puller<br />
OTTO JUNKER GmbH<br />
see Extrusion 2<br />
see Extrusion 2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Section cooling<br />
Profilkühlung<br />
OTTO JUNKER GmbH<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Section saws<br />
Profilsägen<br />
OTTO JUNKER GmbH<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Section store equipment<br />
Profil-Lagereinrichtungen<br />
H+H HERRMANN + HIEBER GMBH<br />
För<strong>de</strong>rsysteme für Paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
see Extrusion 2<br />
see Extrusion 2<br />
E-Mail: Schwichtenberg@giesel.<strong>de</strong><br />
116 ALUMINIUM · 1-2/2008
KASTO Maschinenbau GmbH & Co. KG<br />
Industriestr. 14, D-77855 Achern<br />
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300<br />
kasto@kasto.<strong>de</strong> / www.kasto.<strong>de</strong><br />
Hersteller von Band- und Kreissägemaschinen<br />
sowie Langgut- und Blechlagersystemen<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
� Section transport equipment<br />
Profiltransporteinrichtungen<br />
OTTO JUNKER GmbH<br />
� Stackers / Destackers<br />
Stapler / Entstapler<br />
� Stretching equipment<br />
Reckeinrichtungen<br />
ALUMINIUM · 1-2/2008<br />
see Extrusion 2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
OTTO JUNKER GmbH<br />
see Extrusion 2<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Transport equipment for<br />
extru<strong>de</strong>d sections<br />
Transporteinrichtungen<br />
für Profilabschnitte<br />
H+H HERRMANN + HIEBER GMBH<br />
För<strong>de</strong>rsysteme für Paletten<br />
und schwere Lasten<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 (0) 711 / 9 34 67-0<br />
Fax +49 (0) 711 / 3 46 0911<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
OTTO JUNKER GmbH<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
2.4 Heat treatment<br />
Wärmebehandlung<br />
� Extrusion<br />
Strangpressen<br />
OTTO JUNKER GmbH<br />
� Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
see Casthouse (foundry) 1.5<br />
see Billet Heating Furnaces 2.1<br />
� Custom <strong>de</strong>signed heat<br />
processing equipment<br />
Kun<strong>de</strong>nspezifische<br />
Wärmebehandlungsanlagen<br />
see Extrusion 2<br />
see Extrusion 2<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
Sistem Teknik Ltd. Sti.<br />
see Billet Heating Furnaces 2.1<br />
LIEFERVERZEICHNIS<br />
� Homogenising furnaces<br />
Homogenisieröfen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
see Billet Heating Furnaces 2.1<br />
2.5 Measurement and<br />
control equipment<br />
Mess- und Regeleinrichtungen<br />
� Extrusion plant control systems<br />
Presswerkssteuerungen<br />
SMS Meer GmbH<br />
see Extrusion equipment 2.2<br />
� Hardness measuring<br />
instuments, portable<br />
Härtemessgerät, tragbar<br />
Form+Test Seidner & Co. GmbH<br />
D-88491 Riedlingen<br />
Telefax 07371/9302-98<br />
E-Mail: linke@formtest.<strong>de</strong><br />
117
LIEFERVERZEICHNIS<br />
2.6 Die preparation and care<br />
Werkzeugbereitstellung<br />
und -pflege<br />
Castool Tooling Solutions<br />
(North America)<br />
21 State Crown Bvld<br />
Scarborough Ontario Canada MIV 4B1<br />
Tel.: +1 416 297 1521<br />
Fax: +1 416 297 1915<br />
E-Mail: sales@castool.com<br />
Internet: www.castool.com<br />
Sales Contact: Danny Dann<br />
� Die heating furnaces<br />
Werkzeuganwärmöfen<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
Sistem Teknik Ltd. Sti.<br />
see Billet Heating Furnaces 2.1<br />
� Extrusion dies<br />
Strangpresswerkzeuge<br />
Haarmann Holding GmbH<br />
Ludwigsallee 57<br />
D-52052 Aachen<br />
Telefon: 02 41 / 9 18 - 500<br />
Telefax: 02 41 / 9 18 - 5010<br />
E-Mail: info.holding@haarmann-gruppe.<strong>de</strong><br />
Internet: www.haarmann-gruppe.<strong>de</strong><br />
2.7 Second-hand<br />
extrusion plant<br />
Gebr. Strangpressanlagen<br />
Qualiteam International/ExtruPreX<br />
Champs Elyséesweg 17, NL-6213 AA Maastricht<br />
Tel. +31-43-3 25 67 77<br />
Internet: www.extruprex.com<br />
2.10 Machining of sections<br />
Profilbearbeitung<br />
� Processing of Profiles<br />
Profilbearbeitung<br />
Tensai (International) AG<br />
Extal Division<br />
Steinengraben 40<br />
CH-4051 Basel<br />
Telefon +41 (0) 61 284 98 10<br />
Telefax +41 (0) 61 284 98 20<br />
E-Mail: tensai@tensai.com<br />
2.11 Equipment and<br />
accessories<br />
Ausrüstungen und<br />
Hilfsmittel<br />
MARX GmbH & Co. KG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13 � Inductiv heating equipment<br />
Induktiv beheizte<br />
Erwärmungseinrichtungen<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
� Har<strong>de</strong>ning technology<br />
Härtetechnik<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
Am großen Teich 16+27<br />
D-58640 Iserlohn<br />
Tel. +49 (0) 2371 / 4346-0<br />
Fax +49 (0) 2371 / 4346-43<br />
E-Mail: verkauf@ias-gmbh.<strong>de</strong><br />
Internet: www.ias-gmbh.<strong>de</strong><br />
� Ageing furnace for extrusions<br />
Auslagerungsöfen für<br />
Strangpressprofile<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
LOI Thermprocess GmbH<br />
Am Lichtbogen 29<br />
D-45141 Essen<br />
Germany<br />
Telefon +49 (0) 201 / 18 91-3 10<br />
Telefax +49 (0) 201 / 18 91-53 10<br />
E-Mail: info@loi.<strong>de</strong><br />
Internet: www.loi.<strong>de</strong><br />
see Billet Heating Furnaces 2.1<br />
2.12 Services<br />
Dienstleistungen<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail:<br />
Schwichtenberg@giesel.<strong>de</strong><br />
118 ALUMINIUM · 1-2/2008
3<br />
Rolling mill technology<br />
Walzwerktechnik<br />
3.1 Casting equipment<br />
3.2 Rolling bar machining<br />
3.3 Rolling bar furnaces<br />
3.4 Hot rolling equipment<br />
3.5 Strip casting units and accessories<br />
3.6 Cold rolling equipment<br />
3.7 Thin strip / foil rolling plant<br />
3.8 Auxiliary equipment<br />
3.9 Adjustment <strong>de</strong>vices<br />
3.10 Process technology / Automation technology<br />
3.11 Coolant / lubricant preparation<br />
3.12 Air extraction systems<br />
3.13 Fire extinguishing units<br />
3.14 Storage and dispatch<br />
3.15 Second-hand rolling equipment<br />
3.16 Coil storage systems<br />
3.17 Strip Processing Lines<br />
3.0 Rolling mill Technology<br />
Walzwerktechnik<br />
SMS Demag Aktiengesellschaft<br />
Eduard-Schloemann-Straße 4<br />
D-40237 Düsseldorf<br />
Telefon: +49 (0) 211 881-0<br />
Telefax: +49 (0) 211 881-49 02<br />
Internet: www.sms-<strong>de</strong>mag.com<br />
E-Mail: communications@sms-<strong>de</strong>mag.com<br />
Geschäftsbereiche:<br />
Warmflach- und Kaltwalzwerke<br />
Wiesenstraße 30<br />
D-57271 Hilchenbach-Dahlbruch<br />
Telefon: +49 (0) 2733 29-0<br />
Telefax: +49 (0) 2733 29-2852<br />
Bandanlagen<br />
Wal<strong>de</strong>rstraße 51/53<br />
D-40724 Hil<strong>de</strong>n<br />
Telefon: +49 (0) 211 881-5100<br />
Telefax: +49 (0) 211 881-5200<br />
Elektrik + Automation<br />
Ivo-Beucker-Straße 43<br />
D-40237 Düsseldorf<br />
Telefon: +49 (0) 211 881-5895<br />
Telefax: +49 (0) 211 881-775895<br />
3.1 Casting equipment<br />
Gießanlagen<br />
OTTO JUNKER GmbH<br />
� Melting and holding furnaces<br />
Schmelz- und Warmhalteöfen<br />
ALUMINIUM · 1-2/2008<br />
see Extrusion 2<br />
see Equipment and accessories 2.11<br />
3.1 Gießanlagen<br />
3.2 Walzbarrenbearbeitung<br />
3.3 Walzbarrenvorbereitung<br />
3.4 Warmwalzanlagen<br />
3.5 Bandgießanlagen und Zubehör<br />
3.6 Kaltwalzanlagen<br />
3.7 Feinband-/Folienwalzwerke<br />
3.8 Nebeneinrichtungen<br />
3.9 Adjustageeinrichtungen<br />
3.10 Prozesstechnik / Automatisierungstechnik<br />
3.11 Kühl-/Schmiermittel-Aufbereitung<br />
3.12 Abluftsysteme<br />
3.13 Feuerlöschanlagen<br />
3.14 Lagerung und Versand<br />
3.15 Gebrauchtanlagen<br />
3.16 Coil storage systems<br />
3.17 Bandprozesslinien<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
Geschäftsbereich <strong>Alu</strong>minium<br />
Konstanzer Straße 37<br />
Postfach 170<br />
CH 8274 Tägerwilen<br />
Telefon +41/71/6666666<br />
Telefax +41/71/6666688<br />
E-Mail: aluminium@maerz-gautschi.ch<br />
Kontakt: Stefan Blum, Tel. +41/71/6666621<br />
� Metal filters / Metallfilter<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
� Filling level indicators<br />
and controls<br />
Füllstandsanzeiger und -regler<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
� Melt purification units<br />
Schmelzereinigungsanlagen<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
3.2 Rolling bar machining<br />
Walzbarrenbearbeitung<br />
� Band saws / Bandsägen<br />
SMS Meer GmbH<br />
Ohlerkirchweg 66<br />
D-41069 Mönchengladbach<br />
Tel. +49 (0) 2161 / 3500<br />
Fax +49 (0) 2161 / 3501667<br />
E-Mail: info@sms-meer.com<br />
Internet: www.sms-meer.com<br />
LIEFERVERZEICHNIS<br />
� Bar scalping / Barrenfräsen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Slab milling machines<br />
Barrenfräsmaschinen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
3.3 Rolling bar furnaces<br />
Walzbarrenvorbereitung<br />
� Homogenising furnaces<br />
Homogenisieröfen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
119
LIEFERVERZEICHNIS<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
� Annealing furnaces<br />
Glühöfen<br />
EBNER Industrieofenbau Ges.m.b.H.<br />
Ruflinger Str. 111, A-4060 Leonding<br />
Tel. +43 / 732 / 68 68<br />
Fax +43 / 732 / 68 68-1000<br />
Internet: www.ebner.cc<br />
E-Mail: sales@ebner.cc<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
� Bar heating furnaces<br />
Barrenanwärmanlagen<br />
see Heat treatment 2.4<br />
EBNER Industrieofenbau Ges.m.b.H.<br />
see Annealing furnaces 3.3<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
OTTO JUNKER GmbH<br />
� Roller tracks<br />
Rollengänge<br />
see Extrusion 2<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
3.4 Hot rolling equipment<br />
Warmwalzanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SIEMAG GmbH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Tel.: +49 (0) 2738 / 21-0<br />
Fax: +49 (0) 2738 / 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
� Coil transport systems<br />
Bundtransportsysteme<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Drive systems / Antriebe<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Rolling mill mo<strong>de</strong>rnisation<br />
Walzwerksmo<strong>de</strong>rnisierung<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
Do you need more information?<br />
E-Mail: Schwichtenberg@giesel.<strong>de</strong><br />
� Spools / Haspel<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Hot rolling units /<br />
complete plants<br />
Warmwalzanlagen/Komplettanlagen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Toolings / Werkzeuge<br />
see Extrusion equipment 2.2<br />
3.5 Strip casting units<br />
and accessories<br />
Bandgießanlagen und<br />
Zubehör<br />
� Cores & shells for continuous<br />
casting lines<br />
Cores & shells for continuous<br />
casting lines<br />
Bruno Presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Revamps, equipments & spare parts<br />
for continuous casting lines<br />
Revamps, equipments & spare parts<br />
for continuous casting lines<br />
Bruno Presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
120 ALUMINIUM · 1-2/2008
� Twin-roll continuous casting<br />
lines (complete lines)<br />
Twin-roll continuous casting lines<br />
(complete lines)<br />
Bruno Presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
3.6 Cold rolling equipment<br />
Kaltwalzanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
Mainzer Landstrasse 16<br />
D-60325 Frankfurt am Main<br />
Tel.: +49 69 97 16 81 48<br />
Fax: +49 69 97 16 82 00<br />
E-Mail: juhani.aittola@pesmel.com<br />
Internet: www.pesmel.com<br />
SIEMAG GmbH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Tel.: +49 (0) 2738 / 21-0<br />
Fax: +49 (0) 2738 / 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
SIGNODE® SYSTEM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
Do you need<br />
more<br />
information?<br />
E-Mail:<br />
Schwichtenberg@giesel.<strong>de</strong><br />
ALUMINIUM · 1-2/2008<br />
� Coil annealing furnaces<br />
Bundglühöfen<br />
OTTO JUNKER GmbH<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
www.vits.com<br />
see Cold rolling equipment 3.6<br />
� Coil transport systems<br />
Bundtransportsysteme<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Cold rolling units / complete plants<br />
Kaltwalzanlagen/Komplettanlagen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Drive systems / Antriebe<br />
see Extrusion 2<br />
see Equipment and accessories 2.11<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
LIEFERVERZEICHNIS<br />
� Heating furnaces / Anwärmöfen<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
OTTO JUNKER GmbH<br />
IUT Industriell Ugnsteknik AB<br />
see Extrusion 2<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
Vits Systems GmbH<br />
Winkelsweg 172<br />
D-40764 Langenfeld<br />
Tel.: +49 (0) 2173 / 798-0<br />
Fax: +49 (0) 2173 / 798-244<br />
E-Mail: mt@vits.<strong>de</strong>, Internet: www.vits.com<br />
� Process optimisation systems<br />
Prozessoptimierungssysteme<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
� Process simulation<br />
Prozesssimulation<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Revamps, equipments & spare parts<br />
Revamps, equipments & spare parts<br />
Bruno Presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
121
LIEFERVERZEICHNIS<br />
� Roll exchange equipment<br />
Walzenwechseleinrichtungen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
Windhoff Bahn- und<br />
Anlagentechnik GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
� Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
� Strip shears<br />
Bandscheren<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Trimming equipment<br />
Besäumeinrichtungen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
3.7 Thin strip /<br />
foil rolling plant<br />
Feinband-/Folienwalzwerke<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SIGNODE® SYSTEM GMBH<br />
Packaging Equipment<br />
Non-Ferrous Specialist Team DSWE<br />
Magnusstr. 18, 46535 Dinslaken/Germany<br />
Telefon: +49 (0) 2064 / 69-210<br />
Telefax: +49 (0) 2064 / 69-489<br />
E-Mail: g.laks@signo<strong>de</strong>-europe.com<br />
Internet: www.signo<strong>de</strong>.com<br />
Contact: Mr. Gerard Laks<br />
� Coil annealing furnaces<br />
Bundglühöfen<br />
OTTO JUNKER GmbH<br />
see Equipment and accessories 2.11<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
see Cold colling equipment 3.6<br />
www.vits.com<br />
see Thin strip / foil rolling plant 3.7<br />
� Heating furnaces<br />
Anwärmöfen<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
see Casthouse (foundry) 1.5<br />
OTTO JUNKER GmbH<br />
see Extrusion 2<br />
see Extrusion 2<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
Edisonstraße 5<br />
D-52152 Simmerath<br />
Tel.: +49 (0) 2473 9488-0<br />
Fax: +49 (0) 2473 9488-11<br />
E-Mail: info@schwartz-wba.<strong>de</strong><br />
Internet: www.schartz-wba.<strong>de</strong><br />
Vits Systems GmbH<br />
Winkelsweg 172<br />
D-40764 Langenfeld<br />
Tel.: +49 (0) 2173 / 798-0<br />
Fax: +49 (0) 2173 / 798-244<br />
E-Mail: mt@vits.<strong>de</strong>, Internet: www.vits.com<br />
� Thin strip / foil rolling mills /<br />
complete plant<br />
Feinband- / Folienwalzwerke /<br />
Komplettanlagen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Revamps, equipments & spare parts<br />
Revamps, equipments & spare parts<br />
Bruno Presezzi SpA<br />
Via per Ornago 8<br />
I-20040 Burago Molgora (Mi) – Italy<br />
Tel. +39 039 63502 229<br />
Fax +39 039 6081373<br />
E-Mail: aluminium.<strong>de</strong>pt@brunopresezzi.com<br />
Internet: www.brunopresezzi.com<br />
Contact: Franco Gramaglia<br />
� Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
Do you need<br />
more information?<br />
E-Mail:<br />
Schwichtenberg@giesel.<strong>de</strong><br />
122 ALUMINIUM · 1-2/2008
3.9 Adjustment <strong>de</strong>vices<br />
Adjustageeinrichtungen<br />
� Sheet and plate stretchers<br />
Blech- und Plattenstrecker<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
� Cable sheathing presses<br />
Kabelummantelungspressen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
� Cable undulating machines<br />
Kabelwellmaschinen<br />
SMS Meer GmbH<br />
see Rolling bar machining 3.2<br />
3.10 Process technology /<br />
Automation technology<br />
Prozesstechnik /<br />
Automatisierungstechnik<br />
4Production AG<br />
Produktionsoptimieren<strong>de</strong> Lösungen<br />
A<strong>de</strong>nauerstraße 20, D-52146 Würselen<br />
Tel.: +49 (0) 2405 / 4135-0<br />
info@4production.<strong>de</strong>, www.4production.<strong>de</strong><br />
SIEMAG GmbH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Tel.: +49 (0) 2738 / 21-0<br />
Fax: +49 (0) 2738 / 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
ALUMINIUM · 1-2/2008<br />
� Process control technology<br />
Prozessleittechnik<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
Unitechnik Cieplik & Poppek AG<br />
D-51674 Wiehl, www.unitechnik.com<br />
� Standards and Specifications<br />
Normen und Spezifikationen<br />
ExcSol GmbH<br />
Im Burggarten 23, D-53507 Dernau<br />
Tel.: +49 (0) 2643/90 02 56, info@excsol.<strong>de</strong><br />
Walzwerke / Beratung / Programmierung<br />
*Normen / Spez. in Datenbanken<br />
*Produktkatalog / Prüfungen / Zeugnisse<br />
*Prozess-/Qualitätsmanagement<br />
� Strip thickness measurement<br />
and control equipment<br />
Banddickenmess- und<br />
-regeleinrichtungen<br />
ABB Automation Technologies AB<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 342000<br />
Fax: +46 21 340005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
LIEFERVERZEICHNIS<br />
� Strip flatness measurement<br />
and control equipment<br />
Bandplanheitsmess- und<br />
-regeleinrichtungen<br />
ABB Automation Technologies AB<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 342000<br />
Fax: +46 21 340005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
3.11 Coolant / lubricant<br />
preparation<br />
Kühl-/Schmiermittel-<br />
Aufbereitung<br />
� Rolling oil recovery and<br />
treatment units<br />
Walzöl-Wie<strong>de</strong>raufbereitungsanlagen<br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Filter for rolling oils and<br />
emulsions<br />
Filter für Walzöle und Emulsionen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
123
LIEFERVERZEICHNIS<br />
� Rolling oil rectification units<br />
Walzölrektifikationsanlagen<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
3.12 Air extraction systems<br />
Abluft-Systeme<br />
� Exhaust air purification<br />
systems (active)<br />
Abluft-Reinigungssysteme (aktiv)<br />
Achenbach Buschhütten GmbH<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Demag Aktiengesellschaft<br />
see Rolling mill Technology 3.0<br />
� Filtering plants and systems<br />
Filteranlagen und Systeme<br />
Dantherm Filtration GmbH<br />
Industriestr. 9, D-77948 Friesenheim<br />
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245<br />
E-Mail: info.<strong>de</strong>@danthermfiltration.com<br />
Internet: www.danthermfiltration.com<br />
3.14 Storage and dispatch<br />
Lagerung und Versand<br />
Mainzer Landstrasse 16<br />
D-60325 Frankfurt am Main<br />
Tel.: +49 69 97 16 81 48<br />
Fax: +49 69 97 16 82 00<br />
E-Mail: juhani.aittola@pesmel.com<br />
Internet: www.pesmel.com<br />
SIEMAG GmbH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Tel.: +49 (0) 2738 / 21-0<br />
Fax: +49 (0) 2738 / 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
3.16 Coil storage systems<br />
Bundlagersysteme<br />
SIEMAG GmbH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Tel.: +49 (0) 2738 / 21-0<br />
Fax: +49 (0) 2738 / 21-1299<br />
E-Mail: info@siemag.com<br />
Internet: www.siemag.com<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
3.17 Strip Processing Lines<br />
Bandprozesslinien<br />
� Strip Processing Lines<br />
Bandprozesslinen<br />
BWG Bergwerk- und Walzwerk-<br />
Maschinenbau GmbH<br />
Mercatorstraße 74 – 78<br />
D-47051 Duisburg<br />
Tel.: +49 (0) 203-9929-0<br />
Fax: +49 (0) 203-9929-400<br />
E-Mail: bwg@bwg-online.<strong>de</strong><br />
Internet: www.bwg-online.com<br />
� Colour Coating Lines<br />
Bandlackierlinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
� Strip Annealing Lines<br />
Bandglühlinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
� Stretch Levelling Lines<br />
Streckrichtanlagen<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
� Lithographic Sheet Lines<br />
Lithografielinien<br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
E-Mail: Schwichtenberg@giesel.<strong>de</strong><br />
124 ALUMINIUM · 1-2/2008
4 Foundry<br />
Gießerei<br />
4.1 Work protection and ergonomics<br />
4.2 Heat-resistant technology<br />
4.3 Conveyor and storage technology<br />
4.4 Mould and core production<br />
4.5 Mould accessories and accessory materials<br />
4.6 Foundry equipment<br />
4.7 Casting machines and equipment<br />
4.8 Handling technology<br />
4.9 Construction and <strong>de</strong>sign<br />
4.10 Measurement technology and materials testing<br />
4.11 Metallic charge materials<br />
4.12 Finshing of raw castings<br />
4.13 Melt operations<br />
4.14 Melt preparation<br />
4.15 Melt treatment <strong>de</strong>vices<br />
4.16 Control and regulation technology<br />
4.17 Environment protection and disposal<br />
4.18 Dross recovery<br />
4.19 Gussteile<br />
4.2 Heat-resistent technology<br />
Feuerfesttechnik<br />
� Refractories<br />
Feuerfeststoffe<br />
Promat GmbH – Techn. Wärmedämmung<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
4.3 Conveyor and storage<br />
technology<br />
För<strong>de</strong>r- und Lagertechnik<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
4.5 Mold accessories and<br />
accessory materials<br />
Formzubehör, Hilfmittel<br />
� Fluxes<br />
Flussmittel<br />
Solvay Fluor GmbH<br />
Hans-Böckler-Allee 20<br />
D-30173 Hannover<br />
Telefon +49 (0) 511 / 857-0<br />
Telefax +49 (0) 511 / 857-2146<br />
Internet: www.solvay-fluor.<strong>de</strong><br />
ALUMINIUM · 1-2/2008<br />
4.6 Foundry equipment<br />
Gießereianlagen<br />
� Casting machines<br />
Gießmaschinen<br />
� Solution annealing furnaces/plant<br />
Lösungsglühöfen/anlagen<br />
ERNST REINHARDT GMBH<br />
Postfach 1880, D-78008 VS-Villingen<br />
Tel. 07721/8441-0, Fax 8441-44<br />
E-Mail: info@ernstreinhardt.<strong>de</strong><br />
Internet: www.Ernst-Reinhardt.com<br />
� Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
see Foundry equipment 4.6<br />
LIEFERVERZEICHNIS<br />
4.1 Arbeitsschutz und Ergonomie<br />
4.2 Feuerfesttechnik<br />
4.3 För<strong>de</strong>r- und Lagertechnik<br />
4.4 Form- und Kernherstellung<br />
4.5 Formzubehör, Hilfsmittel<br />
4.6 Gießereianlagen<br />
4.7 Gießmaschinen und Gießeinrichtungen<br />
4.8 Handhabungstechnik<br />
4.9 Konstruktion und Design<br />
4.10 Messtechnik und Materialprüfung<br />
4.11 Metallische Einsatzstoffe<br />
4.12 Rohgussnachbehandlung<br />
4.13 Schmelzbetrieb<br />
4.14 Schmelzvorbereitung<br />
4.15 Schmelzebehandlungseinrichtungen<br />
4.16 Steuerungs- und Regelungstechnik<br />
4.17 Umweltschutz und Entsorgung<br />
4.18 Schlackenrückgewinnung<br />
4.19 Cast parts<br />
see Equipment and accessories 2.11<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Billet Heating Furnaces 2.1<br />
4.7 Casting machines<br />
and equipment<br />
Gießereimaschinen<br />
und Gießeinrichtungen<br />
OTTO JUNKER GmbH<br />
Molten Metall Level Control<br />
Ostra Hamnen 7<br />
SE-430 91 Hono / Schwe<strong>de</strong>n<br />
Tel.: +46 31 764 5520<br />
Fax: +46 31 764 5529<br />
E-mail: sales@precimeter.se<br />
Internet: www.precimeter.se<br />
Sales Contact: Rolf Backberg<br />
� Mould parting agents<br />
Kokillentrennmittel<br />
see Extrusion 2<br />
Schrö<strong>de</strong>r KG<br />
Schmierstofftechnik<br />
Postfach 1170<br />
D-57251<br />
Freu<strong>de</strong>nberg<br />
Tel. 02734/7071<br />
Fax 02734/20784<br />
www.schroe<strong>de</strong>r-schmierstoffe.<strong>de</strong><br />
125
LIEFERVERZEICHNIS<br />
4.8 Handling technology<br />
Handhabungstechnik<br />
Vollert Anlagenbau<br />
GmbH + Co. KG<br />
see Transfer to the casting furnace 1.5<br />
4.9 Construction and<br />
Design<br />
Konstruktion und Design<br />
THERMCON OVENS BV<br />
� <strong>Alu</strong>minium alloys<br />
<strong>Alu</strong>miniumlegierungen<br />
see Extrusion 2<br />
4.11 Metallic charge<br />
materials<br />
Metallische Einsatzstoffe<br />
Scholz AG<br />
Am Bahnhof<br />
D-73457 Essingen<br />
Tel. +49 (0) 7365-84-0<br />
Fax +49 (0) 7365-1481<br />
E-Mail: infoscholz@scholz-ag.<strong>de</strong><br />
Internet: www.scholz-ag.<strong>de</strong><br />
METALLHÜTTENWERKE BRUCH GMBH<br />
Postfach 10 06 29<br />
D-44006 Dortmund<br />
Telefon +49 (0) 231 / 8 59 81-121<br />
Telefax +49 (0) 231 / 8 59 81-124<br />
E-Mail: al-vertrieb@bruch.<strong>de</strong><br />
Internet: www.bruch.<strong>de</strong><br />
METALLHANDELSGESELLSCHAFT<br />
SCHOOF & HASLACHER MBH & CO. KG<br />
Postfach 600714, D 81207 München<br />
Telefon 089/829133-0<br />
Telefax 089/8201154<br />
E-Mail: info@metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
Internet: www.metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
ALERIS Recycling (German Works) GmbH<br />
<strong>Alu</strong>miniumstraße 3<br />
D-41515 Grevenbroich<br />
Telefon +49 (0) 2181/16 45 0<br />
Telefax +49 (0) 2181/16 45 100<br />
E-Mail: recycling@aleris.com<br />
Internet: www.aleris-recycling.com<br />
� Pre alloys / Vorlegierungen<br />
METALLHANDELSGESELLSCHAFT<br />
SCHOOF & HASLACHER MBH & CO. KG<br />
Postfach 600714, D 81207 München<br />
Telefon 089/829133-0<br />
Telefax 089/8201154<br />
E-Mail: info@metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
Internet: www.metallhan<strong>de</strong>lsgesellschaft.<strong>de</strong><br />
� Recycling / Recycling<br />
TRIMET ALUMINIUM AG<br />
Nie<strong>de</strong>rlassung Gelsenkirchen<br />
Am Stadthafen 51-65<br />
D-45681 Gelsenkirchen<br />
Tel.: +49 (0) 209 / 94089-0<br />
Fax: +49 (0) 209 / 94089-60<br />
Internet: www.trimet.<strong>de</strong><br />
TRIMET ALUMINIUM AG<br />
Nie<strong>de</strong>rlassung Harzgero<strong>de</strong><br />
<strong>Alu</strong>miniumallee 1<br />
06493 Harzgero<strong>de</strong><br />
Tel.: 039484 / 50-0<br />
Fax: 039484 / 50-100<br />
Internet: www.trimet.<strong>de</strong><br />
4.13 Melt operations<br />
Schmelzbetrieb<br />
OTTO JUNKER GmbH<br />
� Heat treatment furnaces<br />
Wärmebehandlungsanlagen<br />
see Extrusion 2<br />
see Billet Heating Furnaces 2.1<br />
� Melting furnaces<br />
Schmelzöfen<br />
Büttgenbachstraße 14<br />
D-40549 Düsseldorf/Germany<br />
Tel.: +49 (0) 211 / 5 00 91-43<br />
Fax: +49 (0) 211 / 50 13 97<br />
E-Mail: info@bloomeng.<strong>de</strong><br />
Internet: www.bloomeng.com<br />
Sales Contact: Klaus Rixen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Equipment and accessories 2.11<br />
MARX GmbH & Co. KG<br />
Lilienthalstr. 6-18<br />
D-58638 Iserhohn<br />
Tel.: +49 (0) 2371 / 2105-0, Fax: -11<br />
E-Mail: info@marx-gmbh.<strong>de</strong><br />
Internet: www.marx-gmbh.<strong>de</strong><br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
� Holding furnaces<br />
Warmhalteöfen<br />
Büttgenbachstraße 14<br />
D-40549 Düsseldorf/Germany<br />
Tel.: +49 (0) 211 / 5 00 91-43<br />
Fax: +49 (0) 211 / 50 13 97<br />
E-Mail: info@bloomeng.<strong>de</strong><br />
Internet: www.bloomeng.com<br />
Sales Contact: Klaus Rixen<br />
see Equipment and accessories 2.11<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
126 ALUMINIUM · 1-2/2008
� Heat treatment furnaces<br />
Wärmebehandlungsanlagen<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Equipment and accessories 2.11<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
4.14 Melt preparation<br />
Schmelzvorbereitung<br />
OTTO JUNKER GmbH<br />
� Degassing, filtration<br />
Entgasung, Filtration<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: http://www.drache-gmbh.<strong>de</strong><br />
� Melt treatment agents<br />
Schmelzebehandlungsmittel<br />
maerz-gautschi<br />
Industrieofenanlagen GmbH<br />
see Casting Equipment 3.1<br />
4.15 Melt treatment <strong>de</strong>vices<br />
Schmelzbehandlungseinrichtungen<br />
OTTO JUNKER GmbH<br />
Metaullics Systems Europe B.V.<br />
P.O.Box 748<br />
NL-2920 CA Krimpen a/d Yssel<br />
Tel. +31-180/590890<br />
Fax +31-180/551040<br />
E-Mail: info@metaullics.nl<br />
Internet: www.metaullics.com<br />
ALUMINIUM · 1-2/2008<br />
see Extrusion 2<br />
see Extrusion 2<br />
4.16 Control and<br />
regulation technology<br />
Steuerungs- und<br />
Regelungstechnik<br />
� HCL measurements<br />
HCL Messungen<br />
OPSIS AB<br />
Box 244, S-24402 Furulund, Schwe<strong>de</strong>n<br />
Tel. +46 (0) 46-72 25 00, Fax -72 25 01<br />
E-Mail: info@opsis.se<br />
Internet: www.opsis.se<br />
4.17 Environment protection<br />
and disposal<br />
Umweltschutz und<br />
Entsorgung<br />
� Dust removal / Entstaubung<br />
NEOTECHNIK GmbH<br />
Entstaubungsanlagen<br />
Postfach 110261, D-33662 Bielefeld<br />
Tel. 05205/7503-0, Fax 05205/7503-77<br />
info@neotechnik.com, www.neotechnik.com<br />
5<br />
LIEFERVERZEICHNIS<br />
� Flue gas cleaning<br />
Rauchgasreinigung<br />
Dantherm Filtration GmbH<br />
Industriestr. 9, D-77948 Friesenheim<br />
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245<br />
E-Mail: info.<strong>de</strong>@danthermfiltration.com<br />
Internet: www.danthermfiltration.com<br />
4.18 Dross recovery<br />
Schlackenrückgewinnung<br />
OTTO JUNKER UK<br />
4.19 Cast parts / Gussteile<br />
TRIMET ALUMINIUM AG<br />
Nie<strong>de</strong>rlassung Harzgero<strong>de</strong><br />
<strong>Alu</strong>miniumallee 1<br />
06493 Harzgero<strong>de</strong><br />
Tel.: 039484 / 50-0<br />
Fax: 039484 / 50-100<br />
Internet: www.trimet.<strong>de</strong><br />
Materials and Recycling<br />
Werkstoffe und Recycling<br />
� Granulated aluminium<br />
<strong>Alu</strong>miniumgranulate<br />
ECKA Granulate Austria GmbH<br />
Bürmooser Lan<strong>de</strong>sstraße 19<br />
A-5113 St. Georgen/Salzburg<br />
Telefon +43 6272 2919-12<br />
Telefax +43 6272 8439<br />
Kontakt: Ditmar Klein<br />
E-Mail: d.klein@ecka-granules.com<br />
see Extrusion 2<br />
Do you need more information?<br />
E-Mail: Schwichtenberg@giesel.<strong>de</strong><br />
<strong>Alu</strong>-<strong>web</strong>.<strong>de</strong><br />
<strong>de</strong>r ALUMINIUM-<br />
Branchentreff.<br />
Haben Sie schon Ihren<br />
Basiseintrag bestellt?<br />
Nein, dann sofort anrufen:<br />
0511/73 04-142<br />
Stefan Schwichtenberg<br />
127
LIEFERVERZEICHNIS<br />
6<br />
Machining and Application<br />
Bearbeitung und Anwendung<br />
� Machining of aluminium<br />
<strong>Alu</strong>miniumbearbeitung<br />
Haarmann Holding GmbH<br />
see Die preparation and care 2.6<br />
6.1 Surface treatment<br />
processes<br />
Prozesse für die<br />
Oberflächenbehandlung<br />
Henkel KGaA<br />
D-40191 Düsseldorf<br />
Tel. +49 (0) 211 / 797-30 00<br />
Fax +49 (0) 211 / 798-36 36<br />
Internet: www.henkel-technologies.com<br />
� Adhesive bonding / Verkleben<br />
Henkel KGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Anodising / Anodisation<br />
Henkel KGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Cleaning / Reinigung<br />
Henkel KGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Joining / Fügen<br />
Henkel KGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Pretreatment before coating<br />
Vorbehandlung vor <strong>de</strong>r Beschichtung<br />
Henkel KGaA<br />
siehe Prozesse für die Oberflächentechnik 6.1<br />
� Thermal coating<br />
Thermische Beschichtung<br />
Berolina Metallspritztechnik<br />
Wesnigk GmbH<br />
Pappelhain 30<br />
D-15378 Hennickendorf<br />
Tel.: +49 (0) 33434 / 46060<br />
Fax: +49 (0) 33434 / 46701<br />
E-Mail: info@metallspritztechnik.<strong>de</strong><br />
Internet: www.metallspritztechnik.<strong>de</strong><br />
6.2 Semi products<br />
Halbzeuge<br />
� Wires / Drähte<br />
DRAHTWERK ELISENTAL<br />
W. Erdmann GmbH & Co.<br />
Werdohler Str. 40, D-58809 Neuenra<strong>de</strong><br />
Postfach 12 60, D-58804 Neuenra<strong>de</strong><br />
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044<br />
E-Mail: info@elisental.<strong>de</strong><br />
Internet: www.elisental.<strong>de</strong><br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail:<br />
Schwichtenberg@giesel.<strong>de</strong><br />
6.3 Equipment for forging<br />
and impact extrusion<br />
Ausrüstung für Schmie<strong>de</strong>und<br />
Fließpresstechnik<br />
� Hydraulic Presses<br />
Hydraulische Pressen<br />
LASCO Umformtechnik GmbH<br />
Hahnweg 139, D-96450 Coburg<br />
Tel. +49 (0) 9561 642-0<br />
Fax +49 (0) 9561 642-333<br />
E-Mail: lasco@lasco.<strong>de</strong><br />
Internet: www.lasco.com<br />
8 Literature<br />
Literatur<br />
� Technikcal literature<br />
Fachliteratur<br />
Taschenbuch <strong>de</strong>s Metallhan<strong>de</strong>ls<br />
Fundamentals of Extrusion Technology<br />
Giesel Verlag GmbH<br />
Verlag für Fachmedien<br />
Ein Unternehmen <strong>de</strong>r Klett-Gruppe<br />
Rehkamp 3 · 30916 Isernhagen<br />
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157<br />
Internet: www.alu-bookshop.<strong>de</strong>.<br />
� Technical journals<br />
Fachzeitschriften<br />
Giesel Verlag GmbH<br />
Ein Unternehmen <strong>de</strong>r Klett-Gruppe<br />
Rehkamp 3 · 30916 Isernhagen<br />
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157<br />
128 ALUMINIUM · 1-2/2008
International<br />
ALUMINIUM<br />
Journal<br />
84. Jahrgang 1.1.2008<br />
Redaktion / Editorial office<br />
Dipl.-Vw. Volker Karow<br />
Chefredakteur, Editor in Chief<br />
Franz-Meyers-Str. 16, 53340 Meckenheim<br />
Tel: +49(0)2225 8359 643<br />
Fax: +49(0)2225 18458<br />
E-Mail: vkarow@online.<strong>de</strong><br />
Dipl.-Ing. Rudolf P. Pawlek<br />
Fax: +41 274 555 926<br />
Hüttenindustrie und Recycling<br />
Dipl.-Ing. Bernhard Rieth<br />
Walzwerkstechnik und Bandverarbeitung<br />
Verlag / Publishing house<br />
Giesel Verlag GmbH, Verlag für Fachmedien,<br />
Unternehmen <strong>de</strong>r Klett-Gruppe, Postfach<br />
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DEF & Communication<br />
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ALUMINIUM ·1-2/2008 129
VORSCHAU / PREVIEW<br />
130<br />
IM NÄCHSTEN HEFT<br />
Special: <strong>Alu</strong>minium-Recycling und Schmelztechnologien<br />
Branchen- und Marktentwicklung, internationale<br />
Herausfor<strong>de</strong>rungen, Technologietrends.<br />
Beiträge unter an<strong>de</strong>rem über:<br />
• Höhere Produktivität von Schmelzöfen durch<br />
schienengebun<strong>de</strong>ne Chargiermaschinen<br />
• Kipptrommelofen ersetzt herkömmlichen<br />
Flammofen zum Schmelzen<br />
• Globale Perspektiven <strong>de</strong>s <strong>Alu</strong>miniumrecyclings<br />
Markt und Technik<br />
• Die „Renaissance“ <strong>de</strong>s Nie<strong>de</strong>rdruckgießens –<br />
CST-Gruppe mit ganzheitlichem Gießtechnologie-<br />
Konzept<br />
Research<br />
Pulvermetallurgische Weiterentwicklung <strong>de</strong>r <strong>Alu</strong>miniumschaumherstellung<br />
durch Einführung schäumbaren<br />
Schüttguts<br />
Erscheinungstermin: 3. März 2008<br />
Anzeigenschluss: 15. Februar 2008<br />
Redaktionsschluss: 14. Februar 2008<br />
Abonnement-Bestellung<br />
� Ja, wir möchten die Zeitschrift ALUMINIUM ab sofort<br />
zum Jahresbezugspreis von EUR 285,- inkl. Mehrwertsteuer<br />
(Ausland EUR 289,-) und Versandkosten abonnieren.<br />
Das Magazin erscheint zehn Mal pro Jahr.<br />
Das Abonnement kann mit einer sechswöchigen Frist<br />
zum Bezugsjahresen<strong>de</strong> gekündigt wer<strong>de</strong>n.<br />
Name / name<br />
Firma / company<br />
Anschrift / address<br />
Umsatzsteuer-I<strong>de</strong>nt.-Nr. / VAT Reg.-No.<br />
Datum / date Unterschrift/Signature<br />
IN THE NEXT ISSUE<br />
Special: <strong>Alu</strong>minium recycling and melting<br />
technologies<br />
Industry and market <strong>de</strong>velopment, global<br />
challenges, trends in technology.<br />
Subjects covered inclu<strong>de</strong>:<br />
• Increased melt furnace productivity by rail-bound<br />
charging machines<br />
• Tilt rotary replacing traditional reverberatory<br />
melting<br />
• Global perspectives of aluminium recycling<br />
Markets and technology<br />
• ‘Renaissance’ of low pressure casting –<br />
CST group’s integrated casting solutions concept<br />
Research<br />
Pow<strong>de</strong>r metallurgical <strong>de</strong>velopment of aluminium<br />
foam production by introduction of foamable bulk<br />
material<br />
Fax: +49 (0) 511 73 04 157<br />
Date of publication: 3 March 2008<br />
Advertisement <strong>de</strong>adline: 15 February 2008<br />
Editorial <strong>de</strong>adline: 14 February 2008<br />
Subscription-Or<strong>de</strong>r<br />
� Yes, we want to subscribe ALUMINIUM. The rate is<br />
EUR 289.00 per year incl. postage. Outsi<strong>de</strong> Europe<br />
US$ 375.00 incl. surface mail, air mail plus US$ 82.00<br />
The magazine is published ten times a year.<br />
Cancellations six weeks prior to the end of a<br />
subscription year.<br />
ALUMINIUM · 1-2/2008
4 5<br />
Media-Informationen<br />
2008<br />
Giesel Verlag GmbH, Rehkamp 3, D-30916 Isernhagen, Telefon +49(0)511 / 7304-0, Telefax +49(0)511 / 7304-157<br />
Ausgabe<br />
1 / 2<br />
3<br />
4<br />
5<br />
6<br />
7 / 8<br />
9<br />
10<br />
11<br />
12<br />
Termine<br />
ET: 05. 02.<br />
AS: 21. 01.<br />
RS: 18. 01.<br />
ET: 03. 03.<br />
AS: 15. 02.<br />
RS: 14. 02.<br />
ET: 04. 04.<br />
AS: 21. 03.<br />
RS: 20. 03.<br />
ET: 02. 05.<br />
AS: 18. 04.<br />
RS: 17. 04.<br />
ET: 02. 06.<br />
AS: 16. 05.<br />
RS: 15. 05.<br />
ET: 01. 08.<br />
AS: 17. 07.<br />
RS: 15. 07.<br />
ET: 01. 09.<br />
AS: 15. 08.<br />
RS: 14. 08.<br />
ET: 02. 10.<br />
AS: 17. 09.<br />
RS: 16. 09.<br />
ET: 03. 11.<br />
AS: 17. 10.<br />
RS: 16. 10.<br />
ET: 01. 12.<br />
AS: 14. 11.<br />
RS: 13. 11.<br />
Themenschwerpunkt / Special<br />
Die internationale Hüttenindustrie:<br />
Verfahren, Anlagen, neue Projekte, Ausrüstungen<br />
und Bezugsquellen<br />
Gezielte Verbreitung in internationalen Hütten und<br />
Umschmelzwerken<br />
Recycling und Schmelztechnologien:<br />
Branchen- und Marktentwicklung, internationale<br />
Herausfor<strong>de</strong>rungen, Technologietrends, Ausrüstungen<br />
und Bezugsquellen<br />
<strong>Alu</strong>miniumbearbeitung:<br />
Neue Entwicklungen und Trends, Verfahren,<br />
Werkzeuge und Maschinen<br />
Die internationale Strangpressindustrie:<br />
Maschinen und Anlagen, Technologien, Messund<br />
Regeltechnik, Projekte, F&E<br />
Gezielte Verbreitung in <strong>de</strong>r internationalen<br />
Strangpressbranche<br />
<strong>Alu</strong>miniumguss:<br />
Neue Technologien, Anlagen, Gießöfen, Formenbau,<br />
Mess- und Regelungstechnik, Ausrüstungen und<br />
Bezugsquellen<br />
Vorschauf auf ALUMINIUM 2008:<br />
Aussteller stellen sich vor,<br />
<strong>de</strong>taillierte Vorberichte<br />
Vorschauf auf ALUMINIUM 2008:<br />
Vorberichte, Firmenporträts,<br />
Aussteller-Interviews und weitere<br />
Informationen im Vorfeld <strong>de</strong>r Messe<br />
Die internationale Walzwerkindustrie:<br />
Walzen, Bandguss, Bandbehandlung – neue Technologien,<br />
Maschinen, Ausrüstungen und Bezugsquellen<br />
Gezielte Verbreitung in <strong>de</strong>r intern. Walzwerkbranche<br />
Oberflächentechnik:<br />
Verfahren, Anlagen, Anwendungen, Qualitätsmanagement,<br />
Liefermöglichkeiten<br />
Fügetechniken:<br />
Technologien, Anlagen, Verfahren, Ausrüstungen,<br />
Anwendungen<br />
Die Themenschwerpunkte bestimmen nicht <strong>de</strong>n Gesamtinhalt. Aktuelle Beiträge<br />
ergänzen die jeweilige Berichterstattung. Än<strong>de</strong>rungen vorbehalten.<br />
Fachteil / Märkte /<br />
Anwendungen<br />
Fachberichte:<br />
Casthouse Solutions<br />
Marktbericht:<br />
China / Asien<br />
Termin- und<br />
Themenplan<br />
Märkte:<br />
<strong>Alu</strong>minium in <strong>de</strong>r Verpackung<br />
Profilbearbeitung:<br />
Spanen, Umformen, Fügen, etc.<br />
Marktbericht:<br />
Produkte und Anwendungen aus<br />
<strong>Alu</strong>miniumguss<br />
Wärmebehandlung von<br />
<strong>Alu</strong>minium:<br />
Anlagen, Verfahren, Projekte,<br />
Ausrüstungen<br />
Leichtbautrends:<br />
Anwendungen, Werkstoffe,<br />
Verfahren, Strategie<br />
Marktberichte:<br />
Die <strong>de</strong>utsche und europäische Walzbranche<br />
<strong>Alu</strong>miniumblech:<br />
Verarbeitung und Anwendung<br />
Märkte:<br />
<strong>Alu</strong>minium im Verkehr<br />
Schweißen von <strong>Alu</strong>minium:<br />
Aktuelle Entwicklungen<br />
Märkte:<br />
<strong>Alu</strong>minium im Bauwesen<br />
Messen /<br />
Veranstaltungen<br />
ALUMINIUM India 2008<br />
22. - 24. 2. 2008<br />
Mumbai, Indien<br />
TMS Annual Meeting<br />
& Exhibition<br />
9. - 13. 3. 2008<br />
New Orleans, USA<br />
Euroguss<br />
11. - 13. 3. 2008<br />
Nürnberg<br />
Hannover Messe<br />
21. - 25. 4. 2008<br />
Metef<br />
9. - 12. 4. 2008<br />
Brescia, Italien<br />
ALUMINIUM CHINA 2008<br />
28. - 30. 5. 2008<br />
Guangzhou, China<br />
O&S<br />
3. - 5. 6. 2008<br />
Stuttgart<br />
euroLITE<br />
24. - 26. 6. 2008, Salzburg<br />
ALUMINIUM 2008<br />
23. - 25. 9. 2008, Essen<br />
11. Int. Conf. on<br />
<strong>Alu</strong>minium Alloy<br />
22. - 26. 9. 2008, Aachen<br />
Interpart<br />
7. - 9. 10. 2008, Karlsruhe<br />
SURFACTS<br />
7. - 9. 10. 2008, Karlsruhe<br />
EuroBlech 2008<br />
21. - 25. 10. 2008, Hannover<br />
parts2clean<br />
28. - 30. 10. 2008, Stuttgart<br />
Bau 2009<br />
12. - 17. 1. 2009<br />
München<br />
ET = Erscheinungstermin AS = Anzeigenschluss RS = Redaktionsschluss
Simply closer to<br />
your products.<br />
Your technology partner in the aluminum industry.<br />
How do we meet the growing <strong>de</strong>mands of our customers<br />
in the aluminum industry worldwi<strong>de</strong>? By supplying<br />
all-inclusive mechatronic solutions. Whatever<br />
you want to manufacture from this material, or what<br />
product quality you aim to achieve – at SMS Demag<br />
we know what it takes. That’s because we listen!<br />
And because we draw on our holistic process know-<br />
how and experience. Our plants – whether new facilities,<br />
conversions or revamps – always ensure that our<br />
solutions encompass the latest <strong>de</strong>velopments in aluminum<br />
production and processing.<br />
Always closer to you – SMS Demag.<br />
SMS DEMAG AG<br />
Eduard-Schloemann-Strasse 4 Phone: +49 (0) 211 881-0 E-mail: communications@sms-<strong>de</strong>mag.com<br />
40237 Düsseldorf, Germany Fax: +49 (0) 211 881-4902 Internet: www.sms-<strong>de</strong>mag.com<br />
MEETING your EXPECTATIONS