special - ALU-WEB.DE

SMS Meer 

6 

Volume 87 · June 2011 

International Journal for Industry, Research and Application 

OFFICIAL INTERNATIONAL 

MEDIA PARTNER 

Special: China 

Special Gifa, Metec, 

Thermprocess, Newcast 

SMS Meer presents world’s 

most powerful modern 

light-alloy extrusion press 

S + C Extrusion Tooling 

Solutions – a competent 

partner for containers 

Aluminium recycling 

industry clearly recovering

Trust... 

Solid competence for the aluminum industry 

Being able to trust in the expertise and performance of every 

team member, is the foundation for success. To our customers 

around the world this means being able to count on a comprehensive 

offering in the area of aluminum production. From 

thermal pre-treatment to shaping and refi ning, we always meet 

the constantly rising challenges of the market. 

Whether in new plant construction or revamp projects, our 

solid process know-how encompasses the complete production 

cycle, including the integration of the latest electrical 

engineering and automation solutions. 

Confi dence through performance – SMS Siemag. 

SMS SIEMAG AG 

Eduard-Schloemann-Strasse 4 Phone: +49 (0) 211 881-0 E-mail: communications@sms-siemag.com 

40237 Düsseldorf, Germany Fax: +49 (0) 211 881-4902 Internet: www.sms-siemag.com

Visit us at 

METEC 2011 

Hall 5, Booth F16 

June 28 to July 2 

in Düsseldorf, Germany

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Please be our guest 

and discover the benefits of the 

Aluminium ePaper yourself in a 

free three-month trial: 

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Volker Karow 

Chefredakteur 

Editor in Chief 

Energie- und Materialeffizienz 

im Fokus der 

Gifa, Metec, Thermprocess 

Energy and material efficiency 

at the focus of Gifa, 

Metec and Thermprocess 

In wenigen Wochen öffnet das Messequartett 

Gifa, Metec, Thermprocess und Newcast 

(GMTN) seine Tore. Die weltweite Gießereibranche 

ist nach der Wirtschaftskrise wieder 

auf einem deutlichen Wachstumskurs und 

auch die Hersteller von Maschinen und Anlagen 

für Hütten- und Walzwerke sowie von 

Industrieöfen verzeichnen eine steigende Auftragskurve. 

All diese Branchen sind stark innovationsgetrieben. 

In der Gießereitechnologie wurden 

die Machbarkeitsgrenzen für innovative 

Gussteile deutlich erweitert. Branchenvertreter 

weisen darauf hin, dass sowohl die Werkstoffeigenschaften 

als auch die Komplexität 

der Geometrie heute ein Niveau erreichen, 

das vor einigen Jahren noch undenkbar war. 

Gleichzeitig werden immer höhere Anforderungen, 

insbesondere an die Präzision und 

Gleichmäßigkeit der Gussprodukte gestellt – 

und erfüllt. Den Gießereien ist es in den vergangenen 

Jahren zudem gelungen, systematisch 

ihre Wertschöpfungskette auszubauen. 

Sie haben sich verstärkt als kompetenter 

Entwicklungspartner ihrer Kunden qualifiziert 

und sind mit hohen Investitionen in die 

mechanische Bearbeitung der Gussteile eingestiegen 

– beides Bereiche, die die Gießereien 

langfristig zu einem wichtigen und unersetzbaren 

Produktionspartner ihrer Kunden werden 

lassen. 

Eine besondere Stärke der Unternehmen 

aus dem Industrieofenbau besteht darin, dass 

sie die Energie- und Materialeffizienz ihrer 

Maschinen und Anlagen, nicht zuletzt angesichts 

trendhaft steigender Rohstoff- und Energiekosten, 

in den vergangenen Jahren weiter 

vorangetrieben haben. Der Messeveranstalter 

trägt diesem Megatrend nach Energie- und 

Ressourceneinsparung durch die „ecoMetals“- 

Kampagne Rechnung, an der sich Aussteller, 

die auf diesen Effizienzfeldern herausragende 

Innovationen aufweisen, beteiligen können. 

Der Verein Deutscher Werkzeugmaschinenfabriken 

(VDW) hat im Übrigen mit „Blue 

Competence“ eine thematisch ähnliche Kampagne 

ins Leben gerufen. Sie informiert in 

Fragen der Nachhaltigkeit und Energieeffizienz, 

was die Branche schon kann und was es 

in Zusammenarbeit mit Kunden und Lieferanten 

noch zu lösen gilt. Dies zeigt, dass Ressourcen- 

und Energieeffizienz ein wichtiger 

Faktor im globalen Wettbewerb ist. 

Eine Hauptrolle in der internationalen Metallurgiebranche 

spielen die italienischen und 

deutschen Hersteller von Hütten- und Walzwerkeinrichtungen, 

die in Düsseldorf stark 

vertreten sein werden. 

Mit mehr als 700 Ausstellern verspricht die 

GMTN, ein Messe-Highlight dieses Jahres zu 

werden. 

EDITORIAL 

In a few weeks the quartet of trade fairs Gifa, 

Metec, Thermprocess and Newcast (GMTN) 

will be opening its doors. After the economic 

crunch the foundry sector worldwide is again 

on growth course and manufacturers of machinery 

and equipment for smelters and rolling 

plants and of industrial furnaces are also 

reporting rising order intakes. 

All these industries are powerfully driven 

by innovation. In foundry technology the limits 

of feasibility for innovative castings have been 

greatly extended. Representatives of the industry 

point out that nowadays both the material 

properties and the geometrical complexity of 

castings have reached levels that were unthinkable 

only a few years ago. At the same time 

continually stricter demands, in particular on 

the precision and uniformity of cast products, 

are both made and fulfilled. In recent years 

foundries have also managed systematically to 

extend their value chain. They have become 

much better qualified as competent development 

partners for their customers and have undertaken 

major investments in the mechanical 

machining of castings – both these fields being 

ones which will in the long term enable foundries 

to become important and irreplaceable 

production partners of their customers. 

A particular strength of furnace engineering 

companies is that in recent years they have advanced 

even farther in developing the energy 

and material efficiency of their machinery and 

equipment, not least in view of the upward 

trend of raw materials and energy costs. The 

fair organisers acknowledge this mega-trend 

toward energy and resource saving with the 

‘ecoMetals’ campaign, in which exhibitors 

with outstanding innovations to show in these 

efficiency sectors can participate. The Association 

of German Machine-tool Manufacturers 

(VDW), with its ‘Blue Competence’, has also 

brought to life a thematically similar campaign. 

This provides information on how questions 

of sustainability and energy efficiency relate 

to production, what the sector can already do, 

and what issues still have to be addressed in 

collaboration with customers and suppliers. 

This demonstrates that efficient resource and 

energy management is an important factor in 

the global competition. 

A main part in the international metallurgy 

branch is played by Italian and German 

manufacturers of smelter and rolling plant 

equipment, who will be strongly represented 

in Düsseldorf. They produce plants for the production 

of crude iron and NF-metal products, 

machinery for metal forming, and downstream 

equipment for the metallurgy sector. 

With more than 700 exhibitors, GMTN 

promises to be a keynote trade fair event of 

this year. 

ALUMINIUM · 6/2011 5

INHALT 

Der Aluminium-Branchentreff 

des Giesel Verlags: www.alu-web.de 

0 

0 

54 79 

82 

EDITORIAL 

Energie- und Material effizienz im Fokus der GMTN-Messe • 

Energy and material efficiency at the focus of GMTN trade fairs .......... 3 

AKTUELLES • NEWS IN BRIEF 

Aus Alcan Engineered Products wird Constellium • 

SMS wirft Auge auf elexis • Honsel-Sanierung vor 

dem Abschluss • Schüco erzielt neuen Umsatzrekord ......................... 8 

Fata awarded the contract for an aluminium 

rolling plant in Oman • Alufoil production on the rise ....................... 9 

GSB International und GDA besiegeln Kooperation 

per Vertrag • „Qualicoat“ feiert Jubiläum ........................................10 

ALUMINIUM Dubai with increasing number of visitors • Novelis expands 

rolling capacity and recycling infrastructure in Asia • Intl Conference on 

Tube and Profile Bending • CEO Jan A. Haugan leaves Qatalum ............11 

WIRTSCHAFT • ECONOMICS 

Aluminiumpreise .........................................................................12 

Produktionsdaten der deutschen Aluminiumindustrie .........................14 

Trimet fordert Energiewende mit Augenmaß ....................................16 

Dubal minimises environmental impact of operations ........................40 

Aluminium glitters as an investment in the GCC region ......................44 

Aluminium recycling industry clearly recovering ................................45 

Swiss aluminium industry: production again at record level ...............48 

Schweizer Aluminiumindustrie produziert wieder auf Rekordniveau ................. 50 

Ökosteuer: Den individuellen Erstattungsanteil steigern ....................51 

SPECIAL CHINA 

Preview of ALUMINIUM China 2011, 13 to 15 July 2011, Shanghai ........18 

China’s aluminium industry at present and its prospects for the future .. 20 

Kampf: the new high speed trimming line, type TRL in production ......26 

SMS Meer präsentiert stärkste moderne Leichtmetall- 

Strangpresse der Welt • SMS Meer presents world’s 

most powerful modern light-alloy extrusion press .............................30 

Zhengzhou Zhongshi Cell Technology: Pots can be turned 

on or off without interrupting power to whole potline ......................36 

Siemens VAI: first coil rolled at Chalco Ruimin 1+3 hot finishing mill .... 38 

SPECIAL GIFA, METEC, THERMPROCESS 2011 

Gifa 2011: So groß wie nie zuvor • Gifa 2011: bigger than ever ......... 54 

Casting technology – advances thanks to know-how .........................55 

Magma presents the economic benefits of casting process simulation ....57 

ABB – comprehensive portfolio for 

foundry and metal-processing industries .........................................59 

ASK Chemicals – leading producer of foundry aids ........................... 60 

Altek Europe awarded Queens Award for Enterprise ......................... 60 

Indutherm: Lösungen für hochwertigen Feinguss in allen Metallen ......61 

25 years of Druckguss Service Deutschland GmbH .............................62 

Klein Anlagenbau: Pneumatische Förderung und Kernsandaufbereitung ...62 

6 ALUMINIUM · 6/2011

StrikoMelter mit verbessertem Wirkungsgrad ...................................63 

Thermprocess 2011: Increasing innovation 

potential by virtue of energy efficiency ...........................................66 

Hertwich – market leader with continuous homogenising plants .........66 

E-Gate – the new high-temperature vacuum door from Eisenmann ......67 

De Winter Engineering supplies melting furnace to Sapa Ghlin ...........68 

ecoMetals campaign shows companies’ innovation prowess ...............68 

LOI recycling technology with outstanding low energy consumption ....69 

BSN Thermprozesstechnik: New artificial ageing line 

for volume production of aluminium engine blocks ...........................70 

Ebner heat treatment furnaces for 

rolling mill II expansion at Constantia Teich .....................................70 

Otto Junker presents an innovative gas-fired 

billet heater for high-efficiency aluminium billet heating ...................71 

Ecomax 4C rounds off Elster‘s series of self recuperative burners ........74 

Metec 2011: Hütten- und Walzwerke – Vorsprung durch innovative 

Anlagentechnik • Metec 2011: Smelting and rolling plants – 

advances due to innovative plant technology ...................................76 

SMS group – a joint stand of 2,000 square metres ...........................78 

Achenbach – Spezialist in Walzwerkanlagen- und 

Folienschneidmaschinenbau • Achenbach – specialist 

in rolling mill and foil slitting machinery .........................................79 

KUNST IN ALUMINIUM • ART IN ALUMINIUM .... 64/65 

TECHNOLOGIE • TECHNOLOGY 

Vollert: Automatisches Langgut- und Kleinteilelager für Profilsysteme • 

Automated oblong and small parts warehouse for profile systems ....... 80 

S + C ETS: Kompetenter Partner für Rezipienten • 

S + C ETS: A competent partner for containers .................................82 

Success for Presezzi Extrusion in USA .............................................87 

COMPANY NEWS WORLDWIDE 

Aluminium smelting • On the move • Bauxite and alumina • 

Recycling and secondary smelting • Aluminium semis • Suppliers .. 88-92 

RESEARCH 

Strangpressen von Profilen aus Aluminiumspänen .............................. 93 

DOCUMENTATION 

Patente .....................................................................................98 

Impressum • Impressum ............................................................. 113 

Vorschau • Preview ................................................................... 114 

BEZUGSQUELLENVERZEICHNIS • 

SUPPLIERS DIRECTORY .................................................... 100 

Inserenten dieser Ausgabe 

List of advertisers 

CONTENTS 

This issue contains enclosures from 

GDA Gesamtverband 

der Aluminiumindustrie 

and 

10th International Conference on 

Technology of Plasticity, ICTP 2011 

to which we draw your kind attention. 

ABB Schweiz AG, Switzerland 27 

Achenbach Buschhütten GmbH 79 

Alteco GmbH, Austria 81 

Aluminium Laufen AG, Switzerland 57 

Atie UNO Informatica, Italy 43 

Aumund Fördertechnik GmbH 73 

Buss AG, Switzerland 89 

BWG Bergwerk- und Walzwerk- 

Maschinenbau GmbH 53 

Carli Precimeter GmbH 56 

Cell-Data International S.r.l., Italy 55 

Coiltec Maschinenvertriebs GmbH 60 

Drache Umwelttechnik GmbH 63 

Dr. Graf – personnel consultancy 9 

Dubai Aluminium Co. Ltd, UAE 15 

Ebner Industrieofenbau GmbH, Austria 34/35 

ECL, France 71 

Eisenmann AG 69 

Elpo GmbH Luft- und Trocknungstechnik 49 

Elster GmbH 67 

Emirates Aluminium, UAE 13 

ESK Ceramics GmbH & Co. KG 87 

Fata Hunter S.p.A, Italy 21 

Gautschi Engineering GmbH, Switzerland 74 

Glama Maschinenbau GmbH 41 

Hertwich Engineering GmbH, Austria 116 

Hubtex Maschinenbau GmbH & Co. KG 59 

I.A.S. Induktions-Anlagen+ 

Service GmbH & Co. KG 83 

Inotherm Industrieofen- 

und Wärmetechnik GmbH 33, 48, 57 

Kind & Co. Edelstahlwerk 

Kommanditgesellschaft 33 

LOI Thermprocess GmbH 47 

Matthies Druckguss GmbH 58 

Messe Düsseldorf 51 

Micro-Epsilon Messtechnik 

GmbH & Co. KG 77 

Bernd Münstermann GmbH & Co. KG 61 

Neotechnik GmbH 61 

Novelis PAE, France 75 

Otto Junker GmbH 39 

Outotec GmbH 115 

PSI Metals GmbH 29 

Rösler Oberflächentechnik GmbH 81 

Schmidt + Clemens GmbH & Co. KG 23 

Selema srl., Italy 31 

Shanghai Jieru, PRC 37 

SMS Siemag AG 2/3 

SRS Amsterdam BV, Netherlands 85 

Storvik AS, Norway 46 

Wagstaff Inc., USA 19 

Zhengzhou Zhongshi Cell 

Technology Co., Ltd, PRC 25 


AKTUELLES 

Aus Alcan Engineered 

Products wird Constellium 

Alcan Engineered Products, zu der auch die 

Alcan Singen GmbH gehört, wird als Ausdruck 

einer neuen Unternehmensidentität in Constellium 

umbenannt. Der Name leitet sich 

vom englischen „Constellation“ für Sternbild 

ab und soll auf die breite Palette hochwertiger 

Aluminiumprodukte verweisen, die das 

Unternehmen gleichsam wie eine Gruppe 

von Sternen anbietet. In Singen stellte das 

Management den Mitarbeitern die neue Marke 

vor, deren Einführung wenige Tage nach 

Ankündigung verschiedener Maßnahmen 

erfolgte, mit denen die Wettbewerbsfähigkeit 

des Werkes erhöht werden soll. Verbunden ist 

dies mit dem Abbau von Arbeitsplätzen, der 

Erhöhung der Arbeitszeit und der Aussicht 

auf die Investition in eine neue Pressenlinie. 

Hubert Zimmermann, Geschäftsführer 

der Alcan Singen GmbH, sagte: „Die Marke 

Constellium bedeutet für uns einen wichtigen 

Neuanfang, die Zeit der unsicheren Zugehörigkeit 

und Ausrichtung ist damit vorbei. 

Wir haben einen neuen Eigentümer und eine 

neue Marke. Zusammen mit der Steigerung 

unserer Wettbewerbsfähigkeit sind dies nun 

die maßgeblichen Orientierungspunkte für 

unseren weiteren Erfolg am Standort. Wir 

haben in den letzten Tagen sehr viele Zweifel 

gehört, und daher ist es mir wichtig, dass wir 

mit der neuen Marke auch ein Zeichen für 

den Standort Singen setzen.“ Damit wird der 

über vier Jahre dauernde Ablöseprozess der 

Marke Alcan in Singen nun abgeschlossen. 

SMS wirft Auge auf elexis 

Die SMS GmbH strebt den Erwerb sämtlicher 

Aktien der elexis AG an. Dazu wird den Aktionären 

ein Barangebot über 19 Euro je Aktie 

gemacht, das deutlich über der aktuellen 

Börsennotierung liegt. Durch die Übernahme 

sollen die komplementären Kompetenzen 

in der Mess- und Regelungstechnik und bei 

qualitätssichernden Systemen weiter ausgebaut 

werden. Außerdem bieten die weiteren 

elexis-Aktivitäten der SMS Diversifikationsmöglichkeit 

in andere Abnehmerbranchen. 

Die geplante Übernahme ist Teil der kürzlich 

angekündigten Strategie, das Wachstum der 

SMS-Gruppe durch selektive Akquisitionen zu 

beschleunigen. Die elexis-Gruppe ist mit ihren 

Tochtergesellschaften in der Fertigungsautomatisierung, 

Antriebstechnik und Qualitätskontrolle 

tätig. 

Honsel-Sanierung vor dem Abschluss 

Der kanadische Automobilzulieferer Martinrea 

International und der Finanzinvestor 

Anchorage übernehmen die insolvente Honsel 

AG. MartinRea übernimmt die Mehrheit 

und die industrielle Führerschaft. Damit ist 

der Verkauf des weltweit operierenden Automobilzulieferers 

innerhalb von sieben Monaten 

eingeleitet. Wie es in einer Presseverlautbarung 

von Honsel heißt, wird MartinRea 

Honsel hat Mitte Januar das 50-millionste Steuerteil für Automatikgetriebe 

ausgeliefert. Allein 2010 produzierte das Unternehmen 

vier Millionen der hochpräzisen Bauteile, die in Automatikgetrieben 

den Schaltvorgang steuern. Foto: Honsel 

alle 4.300 Mitarbeiter übernehmen. Mit dem 

Verkauf seien die wichtigsten Ziele erreicht 

worden, nämlich die Arbeitsplätze zu sichern 

und die Gläubigerinteressen bestmöglich zu 

erfüllen. 

Honsel bleibt im Kern als Einheit bestehen. 

Mit der Sanierung und dem „Neuanfang bei 

Schüco erzielt Umsatzrekord 

Schüco International KG, führender Anbieter 

von Aluminium-, Solar-, Stahl- und Kunststoffsystemen 

für energieeffiziente Gebäudehül- 

len, hat 2010 erstmals einen Umsatz von fast 

2,4 Mrd. Euro erwirtschaftet (+22%). Die Investitionen 

erhöhten sich auf 96 Mio. Euro 

(+136%), nicht zuletzt durch der Kauf der 

Solar-Dünnschichtproduktion der Firma Sunfilm. 

Aufgrund der anhaltenden Stärke des 

deutschen Marktes bei einer unterschiedlichen 

Entwicklung des internationalen Geschäftes 

betrug der Umsatzanteil im Ausland erneut 

fast 50 Prozent. 

Vor allem das deutsche Geschäft in den 

Sparten Metallbau, Solar und Kunststoff entwickelte 

sich dynamisch. Das seit Jahren erfolgreiche 

Flächengeschäft Metallbau wurde 

sukzessive in die europäischen Märkte eingeführt; 

auch in den Märkten des Mittleren 

Ostens, in der Türkei und in China legte das 

Unternehmen zu. Die schwierigen Marktbe- 

Null“ ergibt sich laut Insolvenzverwalter Frank 

Kebekus auch ein Startvorteil im Wettbewerb 

mit anderen Autozulieferern. Kebekus sieht 

in der Entscheidung für MartinRea die „unter 

objektiven Gesichtspunkten beste Lösung 

für Honsel“. Die Trimet Aluminium AG, die 

gegen Ende des Bieterverfahrens ein Angebot 

abgegeben hatte und größter Aluminiumlieferant 

von Honsel ist, kam nicht zum Zuge. 

Der Aluminiumkonzern hatte 

für eine deutsche Industrielösung 

unter Einbeziehung der ZF 

Friedrichhafen geworben. Beide 

Unternehmen pflegen seit Jahren 

enge Geschäftsbeziehungen 

zu Honsel. Trimet ist nicht nur 

größter Aluminiumlieferant von 

Honsel und betreibt seit April 

2010 deren komplette Metallversorgung, 

sondern ist selbst 

Hersteller von Motorblöcken, 

Fahrwerks- und Strukturteilen. 

MartinRea gewinnt, so Honsel, 

einen Leichtbauspezialisten, 

der das Produkt- und Dienstleistungsspektrum 

des Unternehmens ideal ergänze. Insbesondere 

die Druckgussexpertise und das Werkstoff- 

Knowhow von Honsel seien Kompetenzfelder, 

die weltweit ausgebaut werden können. Die 

Vertragswerke sollen in den nächsten Wochen 

unterzeichnet werden. 

dingungen in Spanien, Dubai und Osteuropa 

konnten so kompensiert werden. Die Nachfrage 

aus Italien, Frankreich, den USA und 

Tschechien nach Solarlösungen des Unternehmens 

war ebenfalls hoch. 

Größter Umsatzträger blieb der Metall- 

bau, der mit innovativen, hoch wärmege- 

dämmten Alu-Fenstern und Fassadenkonstruktionen 

1,1 Mrd. Euro (+2%) erlöste. Dies 

war angesichts der anhaltenden Immobilienkrise 

nur durch den Ausbau der Marktanteile 

möglich. Die in den letzten Jahren am stärksten 

gewachsene Solar-Sparte setzte mehr als 

1 Mrd. Euro (+59%) um. Schüco zählt damit 

zu den größten Solarunternehmen und bietet 

mit Wärme, Kälte und Strom aus der Sonne 

eine in der Branche einzigartige Bandbreite. 

Für 2011 erwartet das Unternehmen, dass 

die Renovation im privaten Wohnungsbau 

und auch von Verwaltungsgebäuden Richtung 

Energieeinsparung weitergehen wird. 


Fata Hunter 

Fata awarded the contract for 

an aluminium rolling plant in Oman 

Fata EPC, a division of Fata SpA, located 

in Turin, Italy, was awarded by 

Oman Aluminium Rolling Company the 

USD300 million turnkey EPC (Engineering, 

Procurement and Construction) 

contract for an aluminium rolling plant 

in Oman. This strategically important 

project will be located in Sohar, north of 

Muscat. At a cost of USD385 million, the 

project will provide 275 direct jobs at full 

production. 

With a production capacity of 160,000 tonnes 

per year the facility will contain a Hazelett 

continuous caster, while Fata 

Hunter, a division of Fata SpA., will 

supply a hot rolling mill along with a 

world-class cold rolling and finishing 

equipment. Under an interim agreement, 

Fata began the engineering 

works in January 2011. The company 

estimates the employment levels during construction 

will peak at approx. 1,200 persons. 

The rolling mill will serve the aluminium 

food container and food preservation foil markets, 

along with material for the automotive 

heat exchanger 

and air conditioning 

markets. The 

mill is uniquely 

positioned for the 

growing regional 

demand; however, 

sales are expected 

to reach international 

markets as 

well. 

The mill is being 

supplied molten 

metal from 

Sohar Aluminium 

Company which is 

located next door. 

Sales agreements 

with Garmco 

in Bahrain are in place to market the mill’s 

products until an in-house sales and marketing 

team is established in the coming years. 

Ground-breaking will occur in July 2011 with 

the first production coils targeted for August 

2013. The project is designed to deliver high 

quality and short lead time products to its 

customers. Oman Aluminium Rolling Com- 

Buddy Stemple, CEO of Oman Aluminium Rolling Company (left) and 

Anthony Tropeano, CEO of Fata EPC (right) during the contract signing ceremony 

For subscribers 

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NEWS IN BRIEF 

DR. GRAF – personnel consultancy 

Metal is our business 

We, as an international personnel consultancy, are focused on 

occupying top positions in the Aluminium industry. 

With the experiences we acquired in recent decades, we know 

firsthand what the metal industry demands. We have access to an 

excellent network and very often we can offer immediate support. 

We are looking forward to your approach through, email or phone call. 

E-Mail: office@graf-executives.com 

www.graf-executives.com 

Tel.: +49 (0)7524/99 68-53 

Fax: +49 (0)7524/99 68-54 

pany is currently interviewing forty persons 

to begin training for plant operating jobs and 

four full time management employees are in 

place with more being added to launch the 

business. 

The project fits with the strategy of adding 

value to existing local raw material and developing 

economically attractive downstream 

investments in Oman industries that in turn 

contribute to creating sustainable employment, 

expand the local industrial network an 

well as increase and diversify revenues for the 

local economy. 

Alufoil production on the rise 

Signs of buoyancy continue for the European 

aluminium foil sector with a rise in production 

of 1.3% to 214,400 tonnes for the first 

quarter of 2011 compared with the same 

period in 2010. Thicker alufoil gauges, used 

mainly for the manufacture of semi-rigid foil 

trays and technical applications rose by 6%, 

while thinner gauges, used mainly in flexible 

packaging and household foil, fell slightly 

by 0.7%. Exports outside the EAFA region 

remained stable. Business prospects remained 

positive for the rest of 2011, EAFA executive 

director Stefan Glimm said. 

DR. GRAF – personnel consultancy · Conradin-Kreutzer-Str. 15 · D-88339 Bad Waldsee/Germany 


AKTUELLES 

GSB International und GDA besiegeln Kooperation per Vertrag 

Die Qualitätsgemeinschaft GSB International, 

Schwäbisch Gmünd, und der GDA Gesamtverband 

der Aluminiumindustrie, Düsseldorf, 

haben ihre zu Beginn des Jahres begonnene 

enge Zusammenarbeit vertraglich besiegelt. 

Neuer GSB-Geschäftsführer ist Werner Mader, 

der sich beim GDA seit vielen Jahren 

mit Fragen der Oberfläche und der Korrosion 

beschäftigt. Bis Ende 2011 verlegt die GSB 

ihre Geschäftsstelle nach Düsseldorf, um so 

auch organisatorisch die Voraussetzungen für 

die Zusammenarbeit zu schaffen. Beide Organisationen 

bleiben unabhängig und rechtlich 

selbstständig. 

Die GSB International ist seit mehr als 30 

Jahren Partner für Bauherren, Architekten 

und Metallbauer. Sie ist die weltweit erste 

Qualitätsorganisation für die Beschichtung 

von Bauteilen aus Aluminium und aus Stahl. 

Ziel der Qualitätsgemeinschaft ist, die Qualität 

der Lackierung und Beschichtung von 

Aluminium und Stahl und deren Legierungen 

für den Architekturbereich zu sichern und entsprechend 

dem technischen Fortschritt weiterzuentwickeln. 

Die GSB verspricht sich von der Kooperation 

mit dem GDA, der als Branchenverband 

der Aluminiumindustrie 109 Mitglieder zählt 

und gemessen am deutschen Produktionsvolumen 

über einen Organisationsgrad von 96 

Prozent verfügt, eine engere Zusammenarbeit 

„Qualicoat“ feiert Jubiläum 

Das Qualitätszeichen Qualicoat feiert im 

Herbst sein 25-jähriges Jubiläum. Aus diesem 

Anlass veranstaltet Qualicoat einen Kongress, 

der zusammen mit dem deutschen Generallizenznehmer, 

dem Verband für die Oberflächenveredelung 

von Aluminium (VOA), 

ausgerichtet wird. Der Kongress unter dem 

Motto „25 Years of Excellence“ findet vom 

27. bis 28. Oktober in München statt. Die 

Vorträge werden sich naturgemäß mit der 

Vergangenheit, Gegenwart und Zukunft des 

Qualitätszeichens beschäftigen. Dazu werden 

namhafte Referenten aus aller Welt erwartet. 

Am Abend ist – passend zum feierlichen Anlass 

– ein Galadinner geplant. 

Der zweite Tag ist ausgefüllt mit einem 

Besichtigungsprogramm in die BMW-Welt 

München. Hier werden die Teilnehmer des 

Kongresses auch eingebaute Werkstücke 

mit Qualicoat-Beschichtungen sehen können. 

Ein Besuch von MAN ist ebenfalls für 

mit der deutschen und internationalen Aluminiumindustrie. 

„Aluminium und Oberfläche, 

das gehört zusammen. Wir wollen gemeinsam 

mit dem GDA unsere wegweisende Qualitätssicherung, 

die strategische Positionierung der 

Der neue GSB-Geschäftsführer Werner Mader 

Qualitätsgemeinschaft und damit die weitere 

Verbreitung des GSB-Qualitätszeichens verbessern“, 

erläuterte Hans-Jürgen Alfort die 

Hintergründe für die engere Kooperation von 

GSB und GDA. Die bessere Zusammenarbeit 

zwischen Werkstoff Aluminium, Aluminiumhalbzeug 

und dessen Oberflächenbeschichtung 

trage zur Qualitätssicherung und damit 

zur weiteren Verbreitung des Qualitätszeichens 

bei. Übergreifende Themen im Bereich 

des Umweltschutzes und der Nachhaltigkeit 

könnten durch den GDA und dessen Organisationsverbund 

mit anderen Verbänden besser 

koordiniert und bearbeitet werden. 

„Die Qualität der Produkte wird auch 

durch deren Oberfläche definiert. Deshalb 

müssen wir im beiderseitigen Interesse zusammenarbeiten“, 

sagte GDA-Geschäftsfüh- 

rer Christian Wellner. GDA-Präsident Friedrich 

Brökelmann ergänzte: „Die Aluminiumindustrie 

und ihre Unternehmen haben ein hohes 

Interesse an der Ausführung und Qualität 

der Oberflächenbehandlung, in diesem Fall 

an der Beschichtung.“ Der GDA könne durch 

die zukünftige räumliche Nähe und enge Kooperation 

mit der GSB-Geschäftsstelle seine 

Werkstoffkompetenz bei der strategischen 

Weiterentwicklung der Qualitätsrichtlinien 

einbringen und somit die Erschließung neuer 

Märkte unterstützen. „Unsere Industrie bleibt 

durch die Kooperation mit der Qualitätsgemeinschaft 

in der Position des Handelnden 

und kann proaktiv internationale Richtlinien 

und Normen mitbestimmen und so Nachteile 

und Risiken für die Branche minimieren“, so 

Brökelmann. 

das fachinteressierte Publikum vorgesehen. 

Mittlerweile gibt es mehr als 400 lizenzierte 

Beschichter, 440 gültige Zulassungen für Beschichtungsstoffe 

von mehr als 50 Lieferanten 

und über 50 Zulassungen für alternative Vorbehandlungschemikalien. 

Ein Grund hierfür 

ist das steigende Qualitätsbewusstsein von Architekten 

und Planern sowie die Anspruchshaltung 

der Kunden in Bezug auf die Gewährleistung 

bei beschichteten Oberflächen. Qualicoat 

zielt auf die Nachfrage nach nachhaltig 

wirtschaftlichen und qualitativ hochwertigen 

Oberflächen im Bereich des Metallbaus und 

der Fassade. Dies geschieht durch proaktive 

und prozessübergreifende Prüf- und Qualitätsleistungen 

– angefangen vom Lieferanten 

der Vorbehandlungs- und Beschichtungsstoffe 

bis hin zur Qualitätskontrolle des Endprodukts 

vor der Auslieferung. 

Nähere Informationen finden sich auf der 

Homepage www.Qualicoat.net. 

10 ALUMINIUM · 6/2011 

GDA 

VOA

SMS group 

ALUMINIUM Dubai with increasing number of visitors 

ALUMINIUM Dubai 2011, the second edition 

of the Middle East’s aluminium trade show, 

saw the participation of 177 exhibitors and 

registered 3,000 international visitors, which 

is an increase by eight percent compared with 

the previous event. 

Novelis expands rolling capacity 

and recycling infrastructure in Asia 

Novelis will invest around USD400 million 

to expand its aluminium rolling and recycling 

operations in South Korea in order to satisfy 

the growing demand for its products in Asia 

and the Middle East. The step will include investments 

in both hot and cold rolling operations 

and increase the company’s aluminium 

sheet capacity in Asia to one million tonnes 

a year. The new capacity is expected to come 

on stream in late 2013. 

“Asia is the largest and fastest growing region 

in the world for aluminium, particularly 

in beverage cans, electronics and automobiles, 

and this expansion will allow us to maintain 

our leadership in this dynamic region,” says 

Phil Martens, president and CEO of Novelis. 

The expansion will increase Novelis’ aluminium 

sheet capacity in Asia by more than 50% 

and will also include the construction of a recycling 

centre for used aluminium beverage 

cans and a casting operation with annual pro- 

status of the exhibition as an important networking 

platform that caters to all key players 

of the global aluminium industry. “Several 

exhibitors have already confirmed their participation 

in the next edition of Aluminium 

Dubai,” said Tarek Ali, show manager of ALU- 

MINIUM Dubai, 

Reed Exhibitions. 

In addition to 

attracting companies 

directly 

involved with the 

production of aluminium 

and aluminium 

products, 

the exhibition also 

gathered decision 

makers from 

companies operating 

in the GCC 

and MENA region 

that are involved 

in industries like 

manufacturing and 

processing, building 

and construction, 

packaging, automotive and transport, 

power transmission, factory and machinery 

production as well as metal and commodity 

markets. 

Aluminium Dubai 2011 was inaugurated by His Excellency Ahmed Al Tayer, Governor 

of the Dubai International Financial Centre, supported by Abdulla Bin Kalban, 

president and CEO of Dubal (1 st from left), by Emal president and CEO Saeed Fadl 

Al Mazroui (3 rd from left) and by show manager Tarek Ali, Reed Exhibitions 

The turnout this year underlines the potential 

of the Middle East as a major business destination 

for international suppliers and technology 

partners that aim to the entire value chain of 

the aluminium industry. And it confirms the 

duction capacity in excess of 220,000 tonnes 

of sheet ingot. 

The recycling component of the investment 

is further indication of Novelis’ emphasis on 

recycling as a core part of its business. The 

company currently obtains used aluminium 

beverage cans from across Asia and recycles 

them into new can sheet in partnership with 

third party processors. The new recycling centre 

at Yeongju will be Novelis’ first integrated 

recycling and casting facility in Asia. The company 

is already a leader in can recycling in 

North and South America and in Europe too. 

The recycling investment will be in Novelis’ 

Yeongju plant. The new recycling and casting 

facility is expected to begin operations in 

late 2012. Novelis Korea Ltd, a subsidiary of 

Novelis Inc., has two integrated rolling facilities 

in Yeongju and Ulsan, both of which have 

casting, hot rolling, cold rolling, finishing and 

recycling capabilities. 

NEWS IN BRIEF 

CEO Jan A. Haugan leaves Qatalum 

Qatalum CEO Jan Arve Haugan has decided 

to leave Qatalum to take on a new position 

as president and CEO of Kvaerner. He will 

leave the company at the end of July 2011 at 

the latest. The board of Qatalum Ltd, a 50-50 

joint venture between Qatar Petroleum and 

Hydro, has started the process of recruiting a 

new CEO, who will be announced shortly. 

24/25 Nov 2011, Dortmund, Germany 

Intl Conference on Tube 

and Profile Bending 

The first International Conference on Tube 

and Profile Bending DORP2011 (Dortmunder 

Kolloquium zum Rohr- und Profilbiegen) will 

be taking place from 24 to 25 November 2011 

in Dortmund, Germany. In response to the 

great feedback in the past years, DORP will be 

a two-day as well as international conference 

for the first time. In this way, there will be 

more room for interesting lectures, stimulating 

discussions and an intense exchange of 

experiences and views between industry and 

science on an international level. 

Conference language is English, but there 

will be available a simultaneous translation 

in German language. Companies will be offered 

the opportunity to present themselves 

through sponsorship or by arranging a small 

exhibition stand in the course of the conference. 

Conference topics in brief: 

• Innovative bending processes: improve- 

ment, new processes 

• Process simulation: material model, spring 

back prediction 

• Process limits and improvement: small 

bending radii, cross section deformation, 

wrinkles 

• Process chain: hydroforming, tube end 

forming, tube machining 

• Application of bent parts: high-strength 

materials, semi-finished products 

• Production process: extrusion, rollforming, 

complex geometry 

• Tube and pipe bending control and 

measurement: control strategies, geometry 

inspection 

Contact: Technische Universität Dortmund, 

Institute of Forming Technology and Lightweight 

Construction, Dipl.-Ing. Andres Weinrich, 

Tel: +49-231-755-5678, Email: dorp2011@iul.tudortmund.de, 

www.iul.eu/DORP2011 


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WIRTSCHAFT 

Produktionsdaten der deutschen Aluminiumindustrie 

Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte** 

Produktion 

(in 1.000 t) 

+/in 

% * 

Produktion 

(in 1.000 t) 

+/- 

in % * 

Produktion 

(in 1.000 t) 

+/in 

% * 

Produktion 

(in 1.000 t) 

+/in 

% * 

Feb 25,5 -24,7 50,9 38,6 147,5 26,0 42,6 34,0 

Mrz 30,4 10,3 57,5 26,1 172,3 29,4 51,1 54,7 

Apr 31,0 77,4 51,0 26,5 160,4 32,2 44,1 33,2 

Mai 34,4 96,8 53,5 16,7 162,4 35,3 47,4 41,2 

Jun 34,7 91,1 56,7 16,4 165,5 21,9 53,7 43,2 

Jul 36,5 83,0 49,7 -4,2 158,3 6,2 50,5 23,6 

Aug 36,9 79,9 46,0 6,4 167,6 27,0 48,4 27,1 

Sep 36,0 69,4 53,6 -3,8 161,0 14,2 50,9 17,3 

Okt 37,1 53,2 52,0 -5,4 161,8 12,5 50,7 11,0 

Nov 35,9 46,3 52,6 -4,4 158,2 6,1 50,8 11,8 

Dez 37,2 42,2 41,7 -1,6 123,4 12,9 31,3 17,7 

Jan 11 37,1 37,7 45,2 -1,5 154,9 11,9 44,8 18,2 

Feb 33,8 32,2 49,3 -3,2 161,1 9,2 47,3 11,1 

* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf 

Primäraluminium 

Walzprodukte > 0,2 mm 

Sekundäraluminium 

Press- und Ziehprodukte 


WIRTSCHAFT 

Trimet fordert Energiewende mit Augenmaß 

Strompreise müssen das besondere Profil 

stromintensiver Grundlastabnehmer berücksichtigen 

Das Reaktorunglück in Japan im März 

dieses Jahres hat die energiepolitische 

Diskussion um die Zukunft der Kernenergie 

in Deutschland neu entfacht. Die von 

der Bundesregierung im September 2010 

verabschiedete Laufzeitverlängerung der 

deutschen Kernkraftwerke gerät zur Makulatur. 

Die sieben ältesten Reaktoren, 

die kurzfristig abgeschaltet wurden, gehen 

möglicherweise dauerhaft vom Netz 

und für die verbleibenden zehn Reaktoren 

wird seitens der Regierungsparteien 

ein Abschalttermin innerhalb der nächsten 

zehn bis zwölf Jahre diskutiert. 

Die energieintensiven Industrien, für die eine 

sichere und bezahlbare Grundlastversorgung 

ein essenzieller Wettbewerbsfaktor ist, beobachten 

mit Sorge diese Pläne für eine beschleunigte 

Energiewende, die – so scheint es – vor 

allem auf den Ausbau erneuerbarer Energien 

und, mit Abstrichen, auf Gaskraftwerke setzt. 

Doch schon heute seien die Strompreise in 

vielen europäischen Nachbarländern deutlich 

günstiger als in Deutschland, betonte jüngst 

Heinz-Peter Schlüter, Aufsichtsratsvorsitzender 

der Trimet Aluminium AG – mit einer 

Kapazität von 500.000 Tonnen Deutschlands 

größter Aluminiumproduzent – gemeinsam 

mit Vorstandsmitglied Martin Iffert und Heribert 

Hauck, Leiter des Ressorts Energiewirtschaft, 

in einem Gespräch mit Journalisten. 

Während hierzulande Unternehmen an der 

Strombörse gegenwärtig rund 60 Euro/MWh 

bezahlten, lägen die Industriestromtarife beispielsweise 

in Frankreich oder Schweden bei 

circa 35 bzw. 30 Euro/MWh. 

Für Grundlastabnehmer wie die Aluminiumhütten 

sind Wind- und Solarenergie, deren 

Stromproduktion von Wind und Wetter abhängen, 

keine zuverlässigen Stromlieferanten. 

„Und Strom aus Gaskraftwerken ist für die 

Industrie nicht bezahlbar“, so Schlüter. Das 

gleiche gelte für Steinkohlekraftwerke. Den 

Grundlaststrom, der für die Trimet existenziell 

ist, erzeugten derzeit nur die Stromquellen 

Kernkraft, Braunkohle und Laufwasser. „Vier 

Stunden ohne Stromversorgung und die Produktionsanlagen 

des Unternehmens wären 

irreparabel zerstört“, erklärte Iffert. 

Ohne die stromintensive Industrie wäre 

sicherer Strom „aus der Steckdose“ rund um 

die Uhr nicht möglich. Als Grundlastabneh- 

Entwicklung der Industriestrompreise 

in Deutschland von 2000 bis heute 

Zwischen 2000 und 2010 haben sich die Industriestrompreise in Deutschland um den Faktor 2,5 verteuert. 

mer brauchen die Trimet-Hütten in Essen und 

Hamburg kontinuierlich Strom in konstanter 

Höhe, 24 Stunden am Tag, 7 Tage die Woche 

und 365 Tage im Jahr – fünf Terrawattstunden 

insgesamt, das entspricht einem Fünftel des 

Strombedarfs der gesamten stromintensiven 

Industrie. Damit trage das Unternehmen zur 

notwendigen Grundauslastung der systemrelevanten 

Grundlastkraftwerke bei und leiste 

einen wichtigen Beitrag zur Sicherstellung einer 

verlässlichen Stromversorgung im Lande, 

so die Unternehmensvertreter. 

Die vorübergehende Abschaltung der sieben 

Reaktoren hat das einheimische Stromangebot 

mit einem Schlag um rund 7,5 Prozent 

verringert – auf das Grundlastprofil bezogen 

sogar um 15 Prozent. Für die Trimet bedeute 

der damit einhergehende Preisanstieg von 

acht bis zehn Euro je Megawattstunde einen 

Ergebnisverlust von circa 40 bis 50 Mio. 

Euro aufs Jahr hochgerechnet. „So viel hat 

das Unternehmen bislang in keinem Jahr seit 

seinem Bestehen als Bilanzgewinn ausweisen 

können“, sagte Schlüter. Der genannte Betrag 

entspreche einer Lohnkostenerhöhung von 

26.000 Euro pro Mitarbeiter und Jahr. 

Die Zusatzkosten, die durch die vorübergehende 

Abschaltung der Kernkraftwerke 

entstanden sind, könnten auch nicht teilweise 

an die Kunden weitergeben werden, denn Aluminium, 

wie viele andere Grundstoffe, werde 

zu weltweit einheitlichen Börsenpreisen 

CO 2 -Kosten im Strompreis 


Quelle: VIK 

Grafiken: Trimet

Energiepreisvergleich Europa 

gehandelt. Die Verteuerung der Produktion 

in Deutschland lasse sich daher nicht an die 

Verbraucher weitergeben. 

Energieintensive Unternehmen nur als 

hohe Stromverbraucher zu sehen, greife zu 

kurz, so die Trimet-Manager. „Ohne stromintensive 

Unternehmen wie die Trimet hätten 

wir im Netz keinen „Platz“ für die volatilen 

Einspeisungen aus Wind und Sonne“, machte 

Hauck deutlich. Denn ohne ausreichende 

Grundlastabnahme müssten nachts, mangels 

Stromnachfrage, die Windräder regelmäßig 

abgeschaltet werden. Die Fotovoltaikanlagen 

führten bereits heute an sonnigen Wochenenden 

regelmäßig zu großen Stabilitätsproblemen 

im Netz. Die Aluminiumhütten der Trimet 

leisteten gerade angesichts des beabsichtigten, 

fortschreitenden Baus neuer Wind- und 

Solarkraftwerke einen wichtigen Beitrag zum 

Ausgleich von Stromschwankungen und zur 

Verhinderung von Stromausfällen in einem 

zunehmend hochbelasteten Netz. 

Dafür, dass das Unternehmen mit seinem 

abschaltbaren Grundlastprofil einen wesentlichen 

Beitrag zur Sicherung der Netzstabilität 

in Deutschland leiste, sei eine angemes- 

Volatilität der Windeinspeisung 

Aufgrund der stark schwankenden Stromerzeugung ist Windkraft nicht geeignet, die Versorgung einer 

grundlastabhängigen Produktion sicherzustellen, auch nicht durch den immer weiteren Ausbau von Windkraftkapazitäten 

WIRTSCHAFT 

sene Vergütung gerechtfertigt. Schon in der 

Vergangenheit habe Trimet durch sekundenschnelle 

Abschaltung seiner Elektrolyseöfen 

einen flächendeckenden Stromausfall verhindern 

können. Hauck erinnerte an den Beinahe- 

Blackout des Verbundnetzes im April 2006, 

als das Kreuzfahrtschiff Norwegian Pearl die 

Meyerwerft in Papenburg verließ, eine 380 

kV-Leitung vorübergehend abgeschaltet werden 

musste und es plötzlich zu Netzschwankungen 

kam, die zu einem weiträumigen 

Stromausfall in Europa geführt hatten. Die 

Abschaltung der Elektrolyseöfen bei der Trimet 

trug entscheidend dazu bei, dass sich das 

Netz innerhalb von zwanzig Minuten wieder 

stabilisierte. Die Elektrolyseanlagen können 

quasi als Regelkraftwerke zur Sicherung der 

Netzstabilität eingesetzt werden. Diese Leistung 

müsse vergütet werden, so Hauck. 

Zahlreiche EU-Nachbarn mit stromintensiver 

Industrie haben Strompreismodelle 

entwickelt, die das besondere Profil stromintensiver 

Grundlastabnehmer adäquat berücksichtigen, 

entweder durch spezielle Industriestromtarife 

oder durch die Vergütung 

unverzögert abschaltbarer Grundlastabnahme 

als Beitrag zur Netzstabilität. In Spanien etwa 

betrage die Vergütung bis zu 20 Euro/MWh 

für Abschaltungen von maximal einer Stunde 

pro Tag und maximal 120 Stunden im Jahr. In 

Italien betrage die Vergütung 35 Euro/MWh 

für die Aluminiumhütte auf Sardinien bei 

maximal 20 Abschaltungen im Jahr. In den 

Niederlanden und Slowenien gibt es ebenfalls 

Abschaltvergütungen. Gefordert sei ein „Level 

Playing Field“ in der EU, mit anderen Worten: 

ein Wettbewerb bei gleichen Spielregeln. 

Damit das Unternehmens dauerhaft überleben 

könne, sei eine sichere und wettbewerbsfähige 

Grundlastversorgung unerlässlich. Ein 

Ausstieg aus der Kernenergie dürfe daher nur 

Zug um Zug organisiert werden – gegen die 

Bereitstellung von Grundlaststrom aus anderen 

bezahlbaren Quellen. Außerdem seien 

vergleichbare Strompreismodelle wie bei den 

EU-Nachbarn nötig – entweder als Grundlaststromtarif 

oder als Prämie für das abschaltbare 

Grundlastprofil der Trimet-Hütten. Darüber 

hinaus sei auch eine volle Kompensation der 

indirekten CO2-Kosten im Strom erforderlich, 

denn deren Einpreisung mache heute 25 Prozent 

der Strompreise aus. Dies sei ein politisch 

induzierter Kostenfaktor, der angesichts der 

Preisbildung von Aluminium an den internationalen 

Rohstoffbörsen nicht an den Endverbraucher 

weitergegeben werden kann. Bereits 

im Juni 2009 habe die Bundesregierung diese 

Kompensation entschieden, „passiert ist aber 

nichts“, so die Trimet-Manager. 

� 


Reed Exhibitions 

SPECIAL CHINA 

ALUMINIUM China 2011, 13 to 15 July 2011, Shanghai 

“Weather vane of the developing aluminium industry” 

In some few weeks, the 7 th presentation 

of ‘ALUMINIUM China 2011’ will open 

its door at Shanghai. The event will be 

taking place at Shanghai New International 

Expo Centre for the seventh time, 

once again showcasing the first hand insights 

and latest progress in this exciting 

industry. 

China experienced strong rebound in aluminium 

production in 2010, signalled by the overwhelming 

percentage of export growth against 

2009, in terms of primary aluminium (321%), 

aluminium alloy (112%) and semi-finished 

products (56%). Leading manufacturers predict 

an ongoing significant growth in aluminium 

consumption. China’s packaging industry 

shows strong performance – aluminium foil 

supply accounts for over a third of the total 

annual aluminium consumption in China. 

Rolling out the 12 th Five-Year Plan, China is 

now demanding more leading technologies to 

sharpen its edge in manufacturing more advanced 

products to serve the booming end 

users markets, such as transportation, packaging, 

constructions and home appliances. Huge 

investment is placed in major new launches in 

Henan, Guangxi, Guizhou, Guangdong, Jilin 

and Inner Mongolia, with products covering 

rolling, extrusion and die-casting and equipment 

supplied by international providers from 

Europe and Japan. All these positive trends 

are reflected by the huge turnout at this year’s 

Aluminium China Exhibition, the longest-running 

event in the Asia-Pacific region. 

As part of the global ALUMINIUM trade 

fair series organised by Reed Exhibitions, 

ALUMINIUM China 2011, in an exhibition 

area of 23,000 square metres, is anticipated to 

gather global renowned brands such as Chalco, 

Nanshan Aluminium or Qatar Aluminium 

plus 400 local and international companies 

specialised in various segments covering the 

entire aluminium industry chain as well as to 

draw the attendance of over 10,000 industry 

professionals, representing materials procurement, 

research and development personnel in 

aluminium applications from more than 90 

countries and regions around the world. 

This proven Asia’s No. 1 aluminium trade 

fair will aim at facilitating a world class platform 

dedicated for the whole supply chain in 

the aluminium industry and its major application 

industries. Supported by industry players 

from all over the world, the event will showcase 

innovative products and cutting-edge 

technologies in the three-day exhibition for- 

View of the ALUMINIUM China Exhibition 2010 

mat to industry elites interested in gathering 

market information and purchasing demanded 

materials. 

Edwin Tan, vice president, Business Development 

& Projects, Reed Exhibitions Greater 

China remarks: “The active cooperation of global 

aluminium giants with China fully demonstrates 

the demanding market and the strong 

trend in global resources cooperation in the 

aluminium industry. In this environment, the 

announcements concerning corporate strategies, 

the showcasing of new industrial technology 

and the promotion of new equipment are 

particularly important. ALUMINIUM China 

2011, together with enterprises from all over 

the world, will show the vitality of the aluminium 

industry.” 

To focus on the latest trends and address 

the growing need for training and personal 

development, the organiser also joins hands 

with important organisations in China to play 

host to a number of educational conferences 

alongside the exhibition area. The topics comprehensively 

shed light on the potential and 

opportunities coming out of the country’s new 

development plan and the dynamic application 

sectors such as automotive manufacturing, 

green energy, and environmental building 

etc. Industry authorities like China Non-ferrous 

Metals Industry Association as well as its 

Recycling Metal Branch will be releasing new 

statistics at these conferences while leading 

consultancies in China including Beijing Antaike 

Information Development Co., Ltd will 

contribute to keynotes indicating opportunities 

and challenges created by the changing 

market demand. 

For a second time, the Asian version of SAE 

World Congress – SAE Asia Congress – will 

be held on the second and third day alongside 

the Exhibition. Themed ‘Low Carbon Mobility’, 

the congress will expand its scope from 

last year’s focus ‘EV – Driver for Material Innovation’ 

to a much more in-depth discussion 

about the role materials will play in the nextgeneration 

vehicles. This joint event hosted by 

SAE Asia and Reed Exhibitions is set to attract 

executives from leading automotive manufacturers 

and tier 1 OEMs. 

Another highlight this year will be the 

brand-new event running in parallel – ‘Industrial 

Materials China’, which will embrace, 

among others, copper, magnesium and composites 

materials. This new launch will make 

ALUMINIUM China able to meet the application 

industry’s need for diversified development. 

With three special pavilions covering 

primary aluminium, recycling and aluminium 

auto parts, diplomatically located in the centre 

of the halls, ALUMINIUM China is making its 

solid step to become Asia’s leading platform 

for material solutions. 

Jia Mingxing, vice president and secretary 

general of the China Nonferrous Metals Industry 

Association, comments: “As the weather 

vane of the development of the aluminium 

industry, ALUMINIUM China has once again 

served as a testament of the rapid and healthy 

development of the Chinese aluminium industry 

in the past year. It plays an increasingly 

important role in the global aluminium industry.” 

� 


SPECIAL CHINA 

China’s aluminium industry 

at present and its prospects for the future 

Zitao Wang, Guangzhou; Dr. Jie Zhou, Delft 

75-MN short-stroke extrusion press for billets with diameter of 457 mm, designed and made by Taiyuan 

Heavy Machinery Co. Ltd in China, cuts the stroke by 30% and the non-productive time by 15% in comparison 

with the conventional counterpart 

Rapid development of China’s aluminium 

industry started in 1978 when a sudden 

surge of demands for aluminium products 

occurred as soon as the country’s economic 

reform programme was launched. 

Over a period of 32 years, the development 

has largely been sustained, being 

ahead of China’s annual GDP growth of 

10% on average. In recent years, China 

has become the largest aluminium producing 

and consuming country in the 

world, accounting for about a third of 

the world’s totals. The sustained growth 

of China’s aluminium industry has been 

mainly driven by the increasing domestic 

market demands, attributed to the 

rapid economic development, first in 

China’s coastal regions and in recent 

years in the western and central regions 

with over 50% of China’s population. 

The strong trend of urbanisation has had 

and will continue to have fundamental 

implications for the end-user markets 

of aluminium products for building and 

construction, transport, electric engineering, 

machinery, electronic appliances and 

consumer goods. By the end of 2008, 

China’s urbanisation rate reached a level 

of 45.7%. It is estimated that the urban 

population will reach 52,3% by 2015, 

57.7% by 2020 and 67.8% by 2030. 

Considering the total population of 1.341 

billion people by the end of 2010, the 

further development of the central and 

western regions as well as overall urbanisation 

in the forthcoming years will create 

huge market demands. To meet these 

demands, China’s aluminium industry will 

continue to grow for many years to come. 

In the meantime, ample business opportunities 

will open up to home and global 

equipment suppliers. China’s aluminium 

community will work together with the 

international community to take up the 

common challenges of improving operating 

energy efficiency and promoting the 

use of aluminium as an energy-saving material 

across a wide range of areas. 

At the end of 1978, the Chinese economy 

turned from a centrally planned economy to 

a market economy, resulting in an unprecedented 

acceleration of the economic development. 

Ever since, China’s aluminium industry 

has made dramatic progress. In 1978, the 

output of alumina was only 778,700 tonnes, 

primary aluminium 296,100 tonnes and processed 

aluminium products (mainly extruded 

and flat-rolled products) 105,600 tonnes. In 

2002, China turned from an aluminium-im- 

porting country to a net exporting country of 

aluminium. In 2008, primary aluminium production 

in China was 13.18 million tonnes, accounting 

for 33% of the world’s total (40.16m 

tonnes). 

After 31 years of sustained development, 

in 2009 China produced: 

Alumina 23.793m tonnes 

Primary 

aluminium 

12.965m tonnes 

Secondary 

aluminium 

3.1m tonnes 

Processed 

aluminium 

products 

• Flat-rolled 

products 

• Extruded 

products 

• Wire 

• Forged 

products & 

powders 

17.38m tonnes, 

up 16% y-on-y 

6.15m tonnes, 

including 1.65m t of foils, 

up 15% y-on-y 

8.9m tonnes, including 

6.23m tonnes of architectural 

profiles, up 17.9% y-on-y 

2.2m tonnes, 

up 15.8% y-on-y 

130,000 tonnes, 

up 8.3% y-on-y 

Cast products 1.24m tonnes 

It is important to note that the impressive 

performance of the industry was achieved in 

view of the global economic downturn and 

should be attributed to the strong demands in 

China’s domestic market, helped by a 4 trillion 

RMB (or USD586bn) stimulus package announced 

in November 2008 and implemented 

mostly in 2009. 

In 2010, China produced: 

Alumina 

Primary 

aluminium 

Processed 

aluminium 

products 

• Flat-rolled 

products 

• Extruded 

products 


up 21.6% y-on-y 


up 20.7% y-on-y 


up 16.6% y-on-y 

7.25m tonnes (including 

1.9m tonnes of foils), 

up 17.9% y-on-y 

11m tonnes, up 23.6% y-on-y 

The growth has been in pace with the overall 

economic development in China, indexed 

by GDP, which has generated huge domestic 


SPECIAL CHINA 

demands for aluminium across many end-users 

markets in a country with a population of 

1.341 billion people. The sustained economic 

development led to an average annual GDP 

growth of 10% over the past 32 years (from 

1978 to 2009). In 2010, China’s GDP surged 

10.3% and replaced Japan as the world’s 

second largest economy. It is however important 

to note that China is still a developing 

country with low GDP per capita, being much 

behind the developed countries in the world. 

Nevertheless, collective wealth has been generated 

for strategic investments in the forthcoming 

years and a solid foundation has been 

laid for further development. 

Aluminium consumption per capita is still 

relatively low in China, although its aluminium 

consumption accounts for about 33% of 

the world’s total and enormous growth was 

achieved at an average annual rate of over 

14% from 1996 to 2009 (see Table 1). The 

present level of aluminium consumption per 

capita is far behind that of the developed 

countries (over 25 kg/capita), implying an 

ample scope for further growth. 

Year 

Aluminium 

1996 2000 2007 2009 

consumption 2.17 kg 3.51 kg 9.66 kg 11.6 kg 

per capita 

Table 1: Aluminium consumption per capita in China 

China’s aluminium industry 

in the years to come 

Starting from 2011, China has entered a period 

of the 12 th 5-year plan (2011 to 2015). It 

is a period of strategic importance to build a 

generally prosperous society. It will present 

opportunities and challenges for its aluminium 

Four-high cold rolling mill with roll width of 2,300 

mm, designed and made by Shanghai Tianzhong 

Machinery Co. Ltd. in China, can produce aluminium 

foil at a maximum speed of 1,200 mm/min 

industry as well as for the whole country. In 

this period, China will strive to reach the following 

targets, most of which are relevant to 

its aluminium industry: 

(i) to increase national urbanisation rate from 

47% to 50% 

(ii) to reach an undefined interim goal to 

reduce carbon intensity by 40 to 45% from 

2005 levels by 2020 

(iii) to increase urbanisation rate of Central 

China from 40% to 48% and reduce energy 

intensity by 25% from 2008 levels by 2015 

(iv) to provide a universal basic healthcare 

coverage by 2020 

(v) to increase domestic consumption to 50% 

of GDP from 36% [1]. 

By the end of 2008, China’s urbanisation 

rate reached a level of 45.7%, with 607 million 

urban residents. In 2009, it reached 46.6% 

(i.e. 622m urban residents). In the past years, 

the annual growth rate has been about 1%. 

It is expected that by 2015, the urban population 

rate will reach 52.3% and 67.8% by 

2030. In the long term, the urbanisation rate 

is likely to slow down, but the overall trend 

125-MN double-action extrusion press for billets with diameter of 686 mm, designed by Xi‘an Heavy Machinery 

Research Institute and made by Shanghai Heavy Machinery Co. Ltd in China, can make profiles as 

wide as 1,050 mm and as long as 60 m 

will remain, basically because China has 

21.7% of the world’s population, but only 

7% of the arable land of the world. By 2050, 

nearly 70% of China’s population will live in 

urban areas. Considering the country’s population 

of today (1.341bn) and further growing 

population in the future (1.443bn by 2030 [2]), 

the development of the northeast, western 

and central regions and overall urbanisation 

in the coming years will create huge market 

demands for aluminium products to be used 

in building and construction, in air, road, rail 

and water transport, electric engineering and 

electronic appliances, machinery and consumer 

goods. 

Undoubtedly, in the coming years production 

and consumption of aluminium in China 

will continue to grow, along with the overall 

economic and technological development. 

The two basic challenges that China’s aluminium 

industry is facing are to improve the 

operating energy efficiency and to promote 

the use of aluminium as an energy-saving 

material across a wide range of areas. 

In April 2010, the Chinese government 

decided to eliminate pre-baking anode electrolysis 

tanks less than 100 kA by the end of 

2011 – a decision that has affected 17 producers 

and cut 371,000 tonnes of aluminium 

out of these cells. Since 2000, China has pro- 

moted the use of pre-baked aluminium electrolytic 

cells with an amperage of over 160 

kA. 300 and 350 kA high-amperage pre- 

baked aluminium electrolytic cells have been 

put into operation with production capacity 

of over 100,000 tonnes. 

The strategy of running electrolytic aluminium 

production streamlined with local 

coal mining and electric power generation has 

helped to solve the problem of power shortage 

and increase the capacities of many primary 

aluminium plants in Henan, Shandong 

and Shanxi provinces and the Inner Mongolia 

autonomous region, leading to a massive 

surge of the primary aluminium production 

capacity from less than 1 million tpy in 2000 

to today’s 5 million tpy, accounting for nearly 

50% of China’s total. 

In the downstream aluminium industry, the 

capacities and capabilities are in place to meet 

the increasing market demands in the coming 

years, while new equipment will keep coming 

on stream. China is able to produce aluminium 

foils as thin as 4.5 μm for capacitors. 

It can produce the vast majority of aluminium 

products for a wide range of applications, including 

aluminium body for high-speed trains. 

The challenges that China’s aluminium industry 

is facing are how (i) to promote the use of 

aluminium and compete with other materials, 


Building 

& construction Transport 

(ii) improve product quality, (iii) increase the 

quantities as required by the domestic market, 

(iv) extend the product spectrum, and (v) elim- 

inate the export of primary aluminium and 

aluminium products with low added values. 

End-user markets 

Electric 

engineering 

In China, the foremost use of aluminium is 

in the building and construction sector, followed 

by transport, electric engineering and 

packaging (see Table 2). 

Building and construction: Aluminium is 

extensively used for window and door frames, 

Packaging Machinery Consumer 

goods 

Electronic 

appliance Others 

35% 18% 12% 8% 8% 8% 4% 7% 

Table 2: China’s aluminium consumption in different sectors in 2008 

curtain walls and decorative profiles and 

plates. About 70% of extruded aluminium 

profiles are consumed in building and construction, 

which is a lot more than the proportions 

in Europe (42%) and North America 

(33.7%). There are 561 extrusion companies 

certified to produce profiles for architectural 

applications and there are 13,755 manufacturers 

of windows and doors. 

The strong demands for aluminium started 

early in the 1980s, in response to the booming 

construction business for both residential 

and non-residential buildings. Over a period 

of eight years (1981 to 1988), each year resi- 

Year Aluminium PVC Steel Wood Other 

1981 to 1988 10.9% 1.4% 59.8% 12% 15.9% 

2001 37.2% 33.4% 6.4% 5% 18% 

2009 55% 35% 6% - 4% 

Table 3: Different materials for windows and doors in China 

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SPECIAL CHINA 

dential buildings with a total area of 115 mil- 

lion sqare metres, public and commercial 

buildings with a total area of 75 million sqm, 

and factory buildings with a total area of 80 

million sqm were completed. In 2000, the 

completed residential buildings in cities and 

rural areas had a total area of 1.19 billion sqm, 

commercial buildings 140 million and factory 

buildings nearly 100 million sqm. Now, the 

annual increase of the total area of completed 

buildings amounts to 2 billion sqm. 

In 1990, the market demands for windows 

and doors of all materials were 75.28 million 

sqm. Now, the demands for aluminium windows 

and doors are about 150 million sqm. 

Aluminium takes a market share of about 55% 

(see Table 3), which is much larger than that in 

the EU countries on average. 

The momentum of the growing market demands 

for aluminium has largely been kept, 

along with the economic development initially 

in the costal regions and then expanded to the 

central and western regions. Since 2000, the 

Chinese government has intensified the investments 

in the northeast, western and central 

regions in order to cope with the problem 

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SPECIAL CHINA 

of uneven economic development and reach 

an improved balance in industrialisation and 

quality of life between the inner and coastal 

regions. The northeast, western and central 

regions account for nearly 60% of China’s 

population and the market potential for aluminium 

products is tremendous. 

Air transport and aerospace: The last decade 

witnessed the fast growing use of aluminium 

in land and water transport, and a rapid 

rise of aluminium use in aircraft is yet to come. 

In 2005, National Aviation Industrial Base 

was founded in Xi’an. In 2008, China’s first 

ever jumbo passenger aircraft company was 

officially inaugurated in Shanghai to build aircraft 

with a take-off weight of more than 100 

tonnes, or aircraft with more than 150 seats. 

China’s jumbo jet 

C919 with up to 

200 seats for short- 

to medium-range 

hauls will make 

its maiden flight in 

2014 before being 

delivered to buyers 

in 2016, which 

is expected to boost 

the country’s fledgling 

aviation industry 

to compete 

with Western rivals 

like Boeing and 

Airbus in China’s 

domestic market. 

The country’s first 

fully home-grown 

short-range passen- 

ger aircraft with a 

seating capacity of 

78 to 90, ARJ-21- 

700, will be delivered in 2011. Orders for the 

aircraft received by November 2010 reached 

240. AC313 helicopter with a maximum takeoff 

weight of 13.8 tonnes and a maximum 

range of 900 km has entered the production 

phase. 

China’s sizable aviation market has attracted 

the international aircraft suppliers. 

The number of registered aircraft is more than 

1,000, mostly from Boeing and Airbus (984 

aircraft from both in July 2008). It was estimated 

that by 2026 China would add 3,000 

aircraft to serve the domestic market. By the 

end of 2010, Airbus Tianjin in China delivered 

37 A320 aircraft to eight Chinese air- 

lines, since the plant began its operation in 

September 2008, and delivered the first aircraft 

in June 2009. It will assemble 36 A320 

aircraft in 2011 and increase the production 

capacity to four aircraft a month in 2012. 

In addition to the market demands for aircraft, 

high-end aluminium products have played 

their role in China’s space programme. In 

Chang’e 1 and Chang’e 2 lunar orbiter, Shenzhou 

unmanned and manned spacecraft, 

and Chang Zhen launch vehicles, aluminium 

products were extensively used. China has 

planned unmanned moon landing for 2012, 

with a possible manned lunar mission to follow 

in 2017. 

Road transport: Road vehicles are one of 

the most important end users of aluminium 

and the growth potential seams to be limit- 

less. Aluminium is extensively used in castings 

and extrusions. In 2009, 100 million aluminium 

wheels were produced. It is expected 

that aluminium wheels will soon be applied 

The SMS Meer Shanghai site will produce complete machines for the Chinese market and components for 

customers worldwide Photo: SMS Meer 

to trucks, trailers, coaches and buses. Then, 

the aluminium consumption in road vehicles 

will have a substantial increase. In addition, 

all-aluminium buses have hit the road. All- 

aluminium light trucks and trailers have been 

developed. New-generation energy-saving 

buses are under development. 

In 2009, 13.795 million road vehicles were 

produced in China, including 7.485 million 

passenger cars. In the same year, 13.54 million 

road vehicles were sold. China surpassed 

the US as the largest road vehicle manufacturing 

and consuming country in the world. 

In 2010, China produced 18.270 million road 

vehicles (including 9.576m passenger cars), 

up 32.4% y-o-y. In 2003, China had merely 

4.89 million private cars, but the number exploded 

to 26.05 million in 2009 and 34.43 

million in 2010. China’s long-term target is 

to produce 100 million cars and buses each 

year by 2020. To accommodate the explosive 

growth of road vehicles, between 1998 

and 2009, China built 55,343 km highways. 

In 2010, China built another 8,258 km high- 

ways. In three-year time, China will have the 

most extensive highway system in the world. 

However, the average number of cars 

owned by every 1,000 Chinese citizens was 

only 46 in 2009, compared with US (765, according 

to 2002 data) and Europe including 

the former Soviet Union countries (300), suggesting 

a great deal of room for growth. China 

has been intensively developing battery-powered 

cars and plans to make one million electric 

vehicles a year by 2015. 

Rail transport: The annual investment in 

high-speed train transport amount to 100 billion 

RMB (nearly US- 

D15bn). By the end 

of 2009, the operating 

rail network covered a 

total length of 86,000 

km. In 2010, another 

4,986 km rail network 

was put into operation 

and thus by the end 

of 2010 the operating 

rail network traversed 

the length and breadth 

of the whole country, 

covering a total length 

of 91,000 km. By 

2012, China will have 

a railway network of 

110,000 km, 13,000 

km of which will be 

high-speed rails. By 

2020, the total length 

will reach 120,000 

km. In addition to 

passenger transport, rising demand for freight 

transport is another driver behind the investments 

and growth in rail transport. 

As of 2009, Chinese Railway owned about 

603,082 wagons, 49,355 coaches and 18,922 

locomotives and ran more than 38,000 trains 

daily, including about 3,500 passenger trains. 

High-speed lines connecting major cities, 

reaching a speed up to 350 km/h, have been 

extended at a rapid speed. By the end of September 

2010, China had 7,055 km of highspeed 

railways in operation, ranking first in 

the world in terms of total length and speed. 

China set its first world speed record on 24 

June 2008 when a CRH3 high-speed train hit 

a top speed of 394.3 km/h. In a speed test of 

a new generation of high-speed trains, CRH- 

380A, on 29 September 2010, the original 8car 

train hit a top speed of 416.6 km/h. Then 

on 3 December 2010, CRH-380A’s longer 16- 


car train hit a top speed of 486.1 km/h and 

set a new world operational speed record. 

In September 2009, the Chinese Ministry of 

Railways ordered 100 16-car and 40 eight-car 

new generation high speed trains that run at 

a cruise speed of 350 km/h and a maximum 

of 380 km/h in commercial service from CRS 

Sifang Locomotive and Rolling Stock Co. Ltd. 

China is now leading the world in high-speed 

rail technology. In December 2010, China’s 

largest manufacturer of rail vehicles, China 

South Locomotive and Rolling Stock Corporation 

(CSR), signed an agreement with General 

Electric to establish a 50:50 joint venture 

to manufacture high-speed trains in the US, 

using China’s technology, and jointly explore 

the US high-speed railway market. Aluminium 

is one of the basic materials for the highspeed 

train body structure. Aluminium products 

used tend to be mono-piece, thin-walled, 

hollow, standardised, high performance and 

multi-functional. 

Another area that needs lots of aluminium 

products is the urban rail transit system and 

subways. It has been planned that by 2015, 

there will be 93 subways and urban rail lines 

with a total length of 2,700 km. By 2020, there 

will be 176 subways and urban rail lines with 

a total length of 6,200 km. By 2050, there will 

be 289 subways and urban rail lines with a 

total length of 11,700 km in the cities with 

population over 1.5 million people. China has 

13 cities with population of over 4 million, 26 

cities with population of 2 million and 75 cities 

with population of 1 to 2 million. At present, 

there are 10 cities with subway systems. In 

Shanghai, for example, the subway lines have 

a total length of 420 km, in Beijing 300 km 

(to be extended to 561 km by 2015) and in 

Guangzhou 222 km (to be extended to 470 

km by 2015). Twenty-eight cities have been 

approved to build subway systems. 

Water transport: Aluminium is extensively 

used as plate, sheet, extruded profile, cast and 

forged product in home-made boats, including 

barges, fishing boats, water management 

boats, hydrofoil, jetfoil and ultra-fast boats, 

yachts, hover and sailing boats and catamarans. 

The market demands for wide profiles 

have been on the rise. In 2009, the largest 

home-designed wave-piercing catamaran Far 

East 01 with a length of 60 m, a width of 18 

m, a middle span of 11 m and all aluminium 

hulls was commissioned. 

A relatively new application area of aluminium 

extrusions is in cargo containers for sea, 

road and rail transport. China has the manufacturing 

capacity of 5.8 million TEUs of a 

large variety (over 3,000) and takes a 95% 

market share of the world. 

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SPECIAL CHINA 

Electric engineering and electronic appliances: 

Between 1998 and 2004, China invested 

210 billion RMB (about USD30.8bn) 

in electric power networks in rural areas. In 

the current period of five-year plan (2011 

to 2015), China will invest 60 billion RMB 

(about USD8.8bn) in rural power networks. 

This will create new demands for aluminium 

in power cables and wires. 

In the area of electronic appliances, in 

2010, China produced 245.845 million PCs 

(+35.0% y-o-y), 998.274 million mobile 

phones (+46.4%), 118.3 million TV sets 

(+19.5%) (including 89.375 flat-screen TV 

sets, +32.1%), 73.008 million refrigerators 

(+23.1%), 108.996 million air conditioners 

(+34.9%), 65.25 billion IC chips (+57.4%) 

and 31.333 million programmed control 

switchboard (PCS) lines (down 24.5%). By 

the end of 2010, there were 895 million mobile 

phone users including 47.05 million 3G 

mobile phone users, and 457 million internet 

users. 

Opportunities for home and 

global equipment suppliers 

To support the growth of China’s aluminium 

industry, home-made equipment – including 

Kampf Schneid- und Wickeltechnik 

electrolytic cells, melting furnaces, extrusion 

presses, continuous casting / rolling machines, 

hot, cold and foil rolling mills and ancillary 

equipment – have found their places not only 

in the home market but also in the export 

market. China has succeeded in building 80tonne 

melting furnaces, 7,500-tonne shortstroke 

presses, 10,000- and 12,500-tonne 

double-action extrusion presses and 2,300 

mm four-high cold rolling mills. A 22,500tonne 

extrusion press and 80,000-tonne 

forging press are now in the making. 

The rapid development of the Chinese 

aluminium industry in recent 32 years, along 

with the progressive integration of the Chinese 

economy into the global economy, has provided 

an exciting opportunity for international 

aluminium companies and equipment suppliers. 

Casting machines from the US and extrusion 

presses from Germany have established 

themselves strongly in the Chinese market 

with superb quality and advanced technology. 

These and many others supplying rolling 

mills, surface treatment facilities and window 

and door machines have benefited from the 

tremendous market opportunities and in the 

meantime made invaluable contributions to 

the rapid development of China’s aluminium 

industry. Some have set up joint ventures 

or wholly-owned subsidiaries for equipment 

manufacturing in China. Germany-based SMS 

Meer GmbH, for example, opened a new site 

in Shanghai in October 2010, to manufacture 

machines for the Chinese market and components 

for SMS’s customers around the world. 

SMS Meer Engineering China Ltd employs 

250 people and provides Chinese customers 

with direct access to the complete SMS Meer 

range of services, from installation and commissioning 

to maintenance and modernisation. 

References 

[1] K. Knutsen, China’s changing investment environment: 

2010 and beyond. Presentation at a conference 

on China, 7 May 2010, Worcester Polytechnic 

Institute, MA, USA. 

[2] Chen Wei, Future population trends in China: 

2005-2050, Monash University, September 2009. 

Authors 

Zitao Wang is with the Aluminium Processing Technology 

Service Centre, Guangdong Non-Ferrous 

Metals Society – Processing Academic Committee, 

Guangzhou, China. 

Dr. Jie Zhou is with the Department of Materials 

Science and Engineering, Delft University of Technology, 

Delft, The Netherlands. 

The new high speed trimming line, type TRL in production 

A good relationship between 

film supplier and machine 

builder has led to the development 

of a new high 

performance machine, make 

Kampf Schneid- und Wickeltechnik 

GmbH & Co. KG. 

The company Xiashun Aluminium 

Foil Co., Ltd, one of the market 

leaders for aluminium foil in 

Asia, has great confidence in the 

quality of European products 

particularly in the technological 

solutions of Kampf. Both companies 

can look back on many 

years of successful cooperation. 

The machine described below, 

which entered in production in 

2010, is already the thirteenth 

Kampf machine at Xiashun. 

The Kampf Trimming & Recoiling Line, 

type TRL is applied in the cold rolling mill 

process. Due to the rolling process, the quality 

Slitting cassette Photos: Kampf 

of the material edges deteriorates. The edge is 

trimmed by the TRL and the web is rewound. 

So far Xiashun bought the aluminium tape 

as a raw material for the foil 

processing. In order to take these 

upstream processes for tape production, 

Xiashun invested in a 

completely new production line 

including caster, hot rolling mill, 

cold rolling mill and finishing 

equipment. Kampf, competent 

partner and market leader for 

slitting and winding technology, 

has been chosen as supplier for 

the new high speed trimming and 

recoiling line. 

Kampf has profound process 

knowledge within the processing 

of aluminium tapes. Some 

projects have been successfully 

realised in the past, these are 

tension levelling lines or continuous 

degreasing and annealing 

lines. 

The TRL mainly consists of an unwind, 

several transport sections, a slitting section and 

a rewind. The rewind as well as the unwind 


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SPECIAL CHINA 

for diameters up to 2,800 mm are each 

equipped with a 2- or 3-step-gear. 

High speeds up to 1,500 m/min of materials 

with a thickness up to 600 μm are possible. 

The TRL can basically be laid out for materials 

up to 2 mm. Tensions of more than 40,000 

N are required. As the web tension and thus 

the motor torque are of enormous importance 

for the roll built-up, a drive technology was 

chosen offering a greater degree of torque 

precision. 

Edge trims of a width up to 60 mm to rolls 

up to a diameter of 1,200 mm will be wound 

on a winder which is positioned underneath 

the machine in the cellar. 

The TRL is equipped with four transport 

sections. Two so-called bridle stations compensate 

the coil set. A driver unit transports the 

material into the cross cutting device in that 

material with off-size thicknesses is removed. 

A rotating cross shear is moved up and down 

via eccentric and cuts the material while it is 

continuously be pushed forward. 

CNC controlled slitting cassette 

The slitting section works with roll shear knives 

also called block knives. Only this technology 

allows an accuracy of better than 0.1 mm. In 

addition this slitting technology guarantees a 

minimal edge built-up. Setting of knives is very 

comfortable: the control calculates the exact 

positions of selected values, i. e. material thicknesses, 

selected slit width, knife widths and 

diameters. The knives are then positioned via 

electric actuators. High precision components 

guarantee the reproducibility of these settings. 

In case of knife change the slitting section is 

driven out of working position into setting 

position, the knives are changed and the corresponding 

knife data are fed into the computer. 

Set values are entered on the display 

and the new positioning of the knives is then 

effected fully automatic. The input values are 

completely reproducible. 13 motors and drives 

in total provide for exact horizontal and vertical 

adjustment of the top and bottom knives, 

the drive of the knives and the running in and 

out of the slitting section. The slitting section 

can optionally be equipped for centre cut for 

tape separating. 

The slitting accuracy is the most main focus 

of the trimming line. Beyond that the TRL 

convinces with high productivity which must 

comply with the productivity of the rolling 

mill. The high degree of automation makes 

the line really special. The trimming line is as 

far as possible automated and equipped with 

The Kampf Trimming and Recoiling Line slits and winds aluminium strips for the subsequent aluminium foil manufacturing process 

complex handling systems. Loading and unloading 

of the machine as well as the removal 

of waste material is done ‘at the push of a 

button’. Logistic and transport requirements 

are very high as several coils per hour can be 

produced. 

The large dimensions of the entire line 

made an assembly of single functional units 

necessary. The development team considered 

these interfaces for a later assembly already 

in the early stage of design planning. The single 

components were tested after assembly in 

Wiehl, Germany, and then sent to China for 

installation and commissioning on time. 

This efficient line has produced successfully 

for several months now. The trimming line is a 

high performance plant which meets the high 

requirements of the manufacturer with regard 

to productivity and quality. 

Technical data of the TRL: 

Material thickness: up to 2 mm 

Working width: up to 2,400 mm 

Rewind diameter: up to 2,800 mm 

Speed: up to 1,500 m/min 

Slitting system: individual knife holder 

with roll shear knives for 

edge trim and centre cut 


We are where our customers are! 

More than 40 years of metals expertise. 

Logistics Management 

Production Optimisation 

Transport Control Production Tracking 

Material Management 

Automation 

Energy Management 

Sales Planning 

Inventory Optimisation 

Software Excellence in Metals 

Advanced Planning and Scheduling 

Cockpit 

�� 

Quality Control

SPECIAL CHINA 

Kraftprotz für die Aluminiumverarbeitung – SMS Meer präsentiert 

stärkste moderne Leichtmetall-Strangpresse der Welt 

B. Rieth, Meerbusch 

Es war ein sehr emotionaler Moment, als 

am 5. Mai dieses Jahres Ulrich Vohskämper, 

Produktbereichsleiter Hydraulische 

Pressen bei SMS Meer, und Yan Ji Tai, 

CEO des chinesischen Kunden Shandong 

Yankuang Light Alloy Company, den 

roten Knopf betätigten: Unter Fanfarenklängen 

schwebte ein opernbühnen-großer 

Vorhang zur Seite und ermöglichte den 

über 250 geladenen Gästen aus der Aluminiumindustrie 

– angereist aus 19 Ländern 

– einen ersten Blick auf die größte moderne 

Leichtmetall-Strangpresse der Welt. Mit 

ihrer Länge von 40 Metern, einer Breite 

von 20 Metern und einer Höhe von 12 

Metern war sie in der „Schwerlasthalle“ 

von SMS Meer in Mönchengladbach, de- 

Adding muscle to aluminium processing – 

SMS Meer presents world’s most powerful 

modern light-alloy extrusion press 

B. Rieth, Meerbusch 

It was a very exciting moment on 5 

May 2011 when Ulrich Vohskämper, 

vice president responsible for hydraulic 

presses at SMS Meer, and Yan Ji Tai, 

CEO of the Chinese client Shandong 

Yankuang Light Alloy Company, pressed 

the red button: to the sounds of fanfares, 

curtains large enough to grace an opera 

stage were opened up to give more than 

250 invited aluminium-industry guests 

from 19 countries their first glimpse of 

the world’s most powerful modern lightalloy 

extrusion press. With a length of 40 

metres, a width of 20 metres and a height 

of 12 metres it dominated SMS Meer’s 

‘Heavy Duty’ manufacturing facility in 

Mönchengladbach, a building whose 

enormous dimensions usually dwarf any 

machinery inside it. SMS Meer’s employees, 

who had managed to assemble the 

Yan Ji Tai, CEO von Shandong Yankuang, und Ulrich Vohskämper, Produktbereichsleiter Hydraulische Pressen bei SMS Meer, bei der offiziellen Übergabe der 

150-MN-Großpresse. Mehr als 250 Gäste bei der Vorstellung der Großpresse hatten Gelegenheit, die Anlage aus nächster Nähe zu bestaunen. 

Yan Ji Tai, CEO of Shandong Yankuang, and Ulrich Vohskämper, vice president Hydraulic Presses of SMS Meer, at the official handing-over ceremony of the 

150-MN press. The presentation of the press gave more than 250 guests the opportunity to marvel close up at the large press. 


Fotos: SMS Meer

2,400-tonne colossus in the space of just 

three months thanks to excellent logistical 

planning, were also proudly present 

at the ceremony. Even the size of some 

of the individual components is remarkable: 

the cylinder head, which consists 

of three forgings, is almost six metres 

long, has an internal diameter of about 

2.3 metres and weighs 160 tonnes. The 

container weighs 66 tonnes and has an 

external diameter of 2.3 metres and a 

length of 2.2 metres. The discard shear 

has a cutting force of 8.7 tonnes, which 

is almost the same as the press capacity 

of the smallest extrusion press from SMS 

Meer. 

The new press has been dubbed ‘the world’s 

most powerful modern aluminium-extrusion 

press’ of the ‘Schloemann’ series because of 

its press capacity: 150 MN, or 15,000 tonnes. 

This enables it to process solid aluminium billets 

up to 800 mm in diameter and 2,000 mm 

long into profiles that are up to 1,100 mm wide 

and 60 metres long. 

The importance of the event becomes clear 

ren riesige Dimensionen normale Maschinen 

zumeist klein aussehen lassen, von 

beherrschender Größe. Stolz verfolgten 

auch die Mitarbeiter von SMS Meer die 

Zeremonie, denen es dank hervorragender 

logistischer Planung gelungen war, den 

2.400 Tonnen wiegenden Koloss innerhalb 

von nur drei Monaten zu montieren. 

Selbst seine Einzelteile haben teilweise 

beachtliche Dimensionen: So hat allein 

der aus drei Schmiedeteilen bestehende 

Hauptzylinder eine Länge von fast sechs 

Metern, einen Innendurchmesser von circa 

2,3 Metern und ein Gewicht von 160 

Tonnen. Der Container wiegt 66 Tonnen 

bei einem Außendurchmesser von 2,3 und 

einer Länge von 2,2 Metern. Die Discard 

Shear hat eine Schnittkraft von 8,7 Tonnen. 

Das entspricht fast der Presskraft der 

kleinsten Strangpresse von SMS Meer. 

Das Attribut der „weltweit größten modernen 

Aluminium-Strangpresse“ der Baureihe 

„Schloemann“ verdankt sie ihrer Presskraft 

von 150 MN, das sind 15.000 Tonnen. Damit 

kann die Presse solide Aluminiumbolzen mit 

SLITTING LINE 30μ÷10mm 

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ENGINEERING & 

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aluminium | copper | brass | stainless steel 

performances advantages 

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thickness from 

30μ to 10mm 

speed till 800mpm 

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reduced burrs, absence 

of scratches and marks, 

precise and uniform coils 

rewinding, easy threading 

and maintenance, reduced 

time of machine stops 

special devices 

quick head changing car, 

pneumatic cutting 

groups, burr masher, 

leveller and oiler 

SPECIAL CHINA 

bis zu 800 mm Durchmesser und 2.000 mm 

Länge in bis zu 1.100 mm breite Profile mit 

Längen bis zu 60 Metern umformen. 

Die Bedeutung des Ereignisses wird klar, 

wenn man sich vor Augen hält, dass dies seit 

über 60 Jahren die größte Strangpresse ist, die 

in Europa gebaut wurde. Sie wird aber kein 

Einzelfall bleiben. In der gleichen Halle waren 

bereits Komponenten für die Montage einer 

gleich großen und gleich leistungsstarken weiteren 

Leichtmetall-Strangpresse vorbereitet, 

die in einigen Monaten ebenfalls nach China 

geliefert wird, und zwar an den langjährigen 

SMS-Kunden Nanshan Aluminium Light Alloy 

als eine von 22 neuen SMS-Pressen. 

Die beiden 150-MN-Pressen bekräftigen 

nachhaltig die Marktführerschaft von SMS 

Meer bei Großpressen. Beginnend mit den 

1990er Jahren, als eine 65-MN-Anlage von 

SMS Meer noch als die „Großpresse“ gefeiert 

wurde, hat das Unternehmen eine Vielzahl von 

Pressen größer als 60 MN geliefert. Alleine 

für Anwendungen im Aluminiumbereich sind 

dies neben den beiden 150-MN-Anlagen eine 

Strangpresse mit 70 MN, drei Strangpressen 

mit 82 MN und eine mit 100 MN Presskraft. 

SLITTER FOR COPPER 

thickness 0.06÷0.20 mm 

speed 140 mpm 

our 

programme 

degreasing, coating, 

tension levelling, 

slitter, cut-to-length, 

slab milling, 

oiling, trimming, 

revamping 

SELEMA srl 

Via Prealpi, 8 I-20034 GIUSSANO (MI) ITALY 

phone +39.0362.850701 fax +39.0362.850184 

info@selema.com www.selema.com 


SPECIAL CHINA 

Blick auf den Manipulator für das Handling der Pressscheiben mit dem 52.000 Liter fassenden Hydrauliktank im Hintergrund 

View of the manipulator for loose dummy block handling and the 52,000-litre hydraulic tank 

Mit Ausnahme einer 82-MN-Strangpresse für 

ein neues Werk in USA sind alle diese Pressen 

nach China gegangen. 

Wenngleich chinesische Unternehmen 

auch eigene Strangpressen in allen Größenordnungen 

herstellen, gibt es für diesen Run 

auf die Pressen von SMS Meer einige nachvollziehbare 

Gründe: Axel Bauer, Vertriebsleiter 

Strangpressen bei SMS Meer, erläuterte 

den Einsatz einer großen Strangpresse: „Auf 

Anlagen solchen Ausmaßes werden unter anderem 

Profile für das Verkehrswesen hergestellt. 

Gerade in Ländern wie China ist das 

von großer Bedeutung, da hier momentan viel 

in die Infrastruktur investiert wird.“ Profile 

benötigt China beispielsweise für Hochgeschwindigkeitszüge, 

die künftig auf der neuen 

Trasse zwischen Peking und Shanghai fahren. 

Aluminium wird hier besonders für die Boden-, 

Seiten- und Dachteile der bis zu 27 Meter 

langen Waggons verwendet. 

Das Ziel der chinesischen Regierung, bis 

2020 ein Hochgeschwindigkeits-Eisenbahnnetz 

von 20.000 km Länge aufzubauen, wird 

den SMS-Großpressen auf Jahre eine sichere 

Auslastung bescheren. Darüber hinaus blickt 

man bei SMS Meer gespannt auf ähnliche 

Entwicklungen in Russland, wo bis 2030 

ebenfalls ein Hochgeschwindigkeits-Bahnnetz 

von 11.000 km Länge realistische Formen annimmt. 

Nicht zu vergessen Indien, das Land 

mit dem derzeit längsten Schienennetz und 

einem enormen Modernisierungsbedarf beim 

rollenden Material, und hier nicht nur im 

Hochgeschwindigkeitsbereich, sondern auch 

bei Intercity-, Commuter, Regional-, Metro- 

und Güterwaggons. 

Weltweit rechnet man für die nächsten 15 

Jahre alleine bei Hochgeschwindigkeitsverbindungen 

mit einer Verdreifachung des vorhandenen 

Schienennetzes. 

Bei all diesen Plänen spielt Aluminium 

eine besondere Rolle dank einer 20- bis 30prozentigen 

Gewichtsreduzierung gegenüber 

Stahl. Dies führt zu einer 10- bis 15-prozentigen 

Energieeinsparung. Angesichts der mit 

Blick auf die Beanspruchung des vorhandenen 

Schienennetzes international begrenzten 

Achslasten erlaubt das geringere Gewicht der 

Aluminiumwaggons eine deutliche Steigerung 

der Nutzlast. 

Vorteile aus der Verwendung von Großprofilen 

im Waggonbau ergeben sich durch eine 

geringere Anzahl von Schweißnähten und 

when one bears in mind that this is the largest 

extrusion press that has been built in Europe 

in more than 60 years. And it will not be a 

one-off. There were already components in the 

same workshop awaiting assembly of a lightalloy 

extrusion press of the same size and capacity, 

which will also be shipped to China in 

a few months’ time; the second press is one of 

22 presses from SMS for one of its longstanding 

clients, Nanshan Aluminium Light Alloy. 

Both 150-MN presses strongly emphasise 

SMS Meer’s market leadership when it comes 

Advertisement 

to large presses. Beginning with the 1990s, 

when a 65-MN press from SMS Meer was 

still being acclaimed as large press, the company 

has supplied a number of presses that 

are larger than 60 MN. For applications in the 


aluminium sector alone, there are – in addition 

to the two 150-MN units – a 70-MN extrusion 

press, three 82-MN extrusion presses and one 

press with a capacity of 100 MN. With the exception 

of one of the 82-MN presses, which 

will be for a new plant in the USA, all of these 

presses were destined for China. 

Even though there are also Chinese companies 

that are capable of building extrusion 

presses in all sizes, there are a number of 

plausible reasons for this run on presses from 

SMS Meer: Axel Bauer, sales manager for extrusion 

presses at SMS Meer, explained what 

a large extrusion press is used for: “Plants of 

this size are used to produce among other 

things profiles for transport systems. That 

is of great importance particularly in countries 

such as China, as a great deal is currently 

being invested in the infrastructure.” 

China needs profiles, for example, for the 

high-speed trains that will run on the new 

track between Beijing and Shanghai. Here, 

aluminium is used in particular for the floor, 

side and roof sections of the carriages, which 

can be up to 27 metres long. The Chinese government 

aims to establish a 20,000-km long 

high-speed rail network by 2020 and this will 

ensure that the large presses from SMS have 

a high level of capacity utilisation for years. 

Furthermore, SMS Meer is looking intently at 

similar developments in Russia, where plans 

for an 11,000-km high-speed rail network by 

2030 are also taking shape. And one must 

not forget India, the country that currently 

has the longest rail network and a huge need 

for modernisation of rolling stock, and here 

not only in the high-speed sector but also 

for intercity, commuter, regional, metro and 

goods trains. 

In the next 15 years alone, new links worldwide 

are expected to lead to a tripling of the 

existing high-speed rail network. 

Aluminium plays a special role in all of 

these plans thanks to a 20 to 30 percent weight 

reduction compared with steel. This leads to 

energy savings of 10 to 15 percent. In view of 

the axle load limits that are in place worldwide 

to protect existing rail networks, the reduced 

weight of the aluminium rolling stock leads to 

a significant increase in payload. 

The advantages of using large profiles in the 

manufacture of rolling stock are the smaller 

number of welds, which thus reduces costs, 

and less problems with quality, in other words 

greater productivity when processing the profiles. 

Large profiles are also being used increasingly 

for industrial profiles, shipbuilding, 

the construction of façades, truck and trailer 

structures and applications in transportation 

in general. 

� 

damit geringere Kosten, geringere Qualitätsprobleme, 

das heißt eine höhere Produktivität 

in der Verarbeitung. Großprofile werden in 

zunehmendem Maße auch für Industrieprofile, 

im Schiffbau, im Fassadenbau, für Truck- 

und Trailerkonstruktionen und allgemeine 

Transportaufgaben eingesetzt. 

Die Shandong Yankuang Light Alloy 

Company gehört zur staatlichen Yankuang 

Group. Diese Gruppe ist als eines der 100 bedeutendsten 

Unternehmen Chinas einer der 

führenden chinesischen Hersteller von Aluminium- 

und Chemieprodukten. Ein weiterer 

Schwerpunkt ist die Kohleverflüssigung. SMS 

SPECIAL CHINA 

Meer liefert an Shandong Yankuang insgesamt 

vier Strangpressen für Aluminiumprofile und 

nahtlose Aluminiumrohre. Die Anlagen haben 

Presskräfte von 36, 55, 82 und 150 MN. Das 

Werk in Zoucheng besitzt nach seiner Fertigstellung 

eine Produktionskapazität von etwa 

130.000 Tonnen Aluminiumprofilen pro Jahr. 

Die Inbetriebnahme aller vier Strangpressen 

ist für Anfang 2012 vorgesehen. 

Erfolgskonzept Kurzhub-Frontlader 

Das Konzept der Kurzhub-Frontlader hat sich 

auch bei den Großpressen von SMS Meer 

Tool Steel and Tooling 

COMPETENCE FROM ONE SOURCE 

Kind & Co., Edelstahlwerk, KG · Ningbo Representative Office 

Phone/Fax: +86 (0) 574 830 76702 · Mobil: +86 (0) 188 686 48390 / +86 (0) 188 686 48391 

Email: xiaoqiang.zhang@kind-co.cn · xiangyun.yan@kind-co.cn · Web: www.kind-co.de 

See you at ALUMINIUM CHINA – German Pavillion 7C12 


SPECIAL CHINA 

Gegenholm mit daran befestigten Zugankern Counter platen with fixed tie rods 

durchgesetzt. Bei der 150-MN-Strangpresse 

für Shandong Yankuang handelt es sich konkret 

um eine Kurzhub-Frontladerpresse mit 

Lochvorrichtung. Damit vereint sie mehrere 

Vorteile in sich: einen kurzen und steifen 

Pressenrahmen sowie ein exaktes Laden des 

Blocks auf Pressenmitte, damit verbunden ein 

zentrisches Stauchen und optimiertes Entlüften. 

Spezialanwendungen für 

die gesamte Werkstoffpalette 

Neben den Großpresssen besitzt SMS Meer 

eine besondere Expertise beim Bau von 

Strangpressen für Spezialanwendungen. Von 

insgesamt 73 Strangpressen, die das Unternehmen 

seit 2005 in Auftrag nahm, sind 28 

Pressen, also ein gutes Drittel, dieser Katego- 

rie zuzuordnen. Unter Spezialanwendungen 

versteht SMS Meer zum Beispiel Strangpressen 

für Rohre und Profile aus Edelstahl und 

Nickelbasis-Legierungen, Kupfer, Messing 

und Titan, aber auch für Gold. Solche stranggepressten 

Halbzeuge finden anspruchsvolle 

und vielfältige Anwendung, etwa in der Chemieindustrie, 

bei der Meerwasserentsalzung, 

im Offshorebereich, in der Nukleartechnik 

sowie im Kraftwerk- und Kesselbau. 

Die unterschiedlichen Umformbedingungen 

der verschiedenen Werkstoffe bedingen 

auch sehr differenzierte Auslegungen der 

Pressparameter. So kann die Pressgeschwindigkeit 

von 0.5 mm/sec für Aluminium-Hartlegierungen 

bis zu 800 mm/sec bei Spezialstählen 

variieren. 

Aluminium ist das Haupteinsatzgebiet der 

SMS-Strangpressen. So werden von den rund 

Shandong Yankuang Light Alloy Company 

belongs to the state-owned Yankuang Group. 

This group is one of the 100 most important 

companies in China and one of the country’s 

leading producers of aluminium profiles and 

chemical products; another key activity is coal 

liquefaction. SMS Meer is supplying Shandong 

Yankuang with a total of four extrusion 

presses for aluminium profiles and seamless 

aluminium tube. The presses have capacities 

of 36, 55, 82 and 150 MN. When it is completed, 

the Zoucheng plant will be capable of 

producing some 130,000 tonnes of aluminium 

profiles a year. The commissioning of all four 

extrusion presses is planned for the beginning 

of 2012. 

Successful short-stroke 

front-loading press concept 

The short-stroke front-loading press concept 

has also become established as a feature of 

SMS Meer’s large presses. The 150-MN extrusion 

press for Shandong Yankuang is actually 

a short-stroke front-loading press with piercer. 

It thus combines several benefits: a short and 

rigid press frame and precise loading of the billet 

in the centre of the press, which is coupled 

with centric loading and optimal venting. 

Special applications across 

the whole range of materials 

Besides large presses, SMS Meer has particular 

expertise in the building of extrusion presses 

for special applications. Out of a total order 

volume of 73 extrusion presses that the company 

has received since 2005, 28 presses, in 

other words a good third, fall into this category. 

For SMS Meer, special applications 

are for example extrusion presses for tube 

and profiles made from stainless steel, nickelbase 

alloys, copper, brass and titanium, and 

even from gold. Such extruded semi-finished 

products are used for demanding and diverse 

applications, such as in the chemical industry, 

seawater desalination, the offshore sector, nuclear 

technology and in power plant construction 

and boilermaking. 

The differing forming characteristics of the 

various materials also call for very differing 

design parameters for the presses: the extrusion 

speed can range from 0.5 mm/sec for hard 

aluminium alloys up to 800 mm/sec for special 

steels. 

Aluminium is the main area of application 

of SMS Meer’s extrusion presses. Of some 400 

extrusion presses that the company has built in 

the past 30 years, about 80 percent have been 

for plants in this sector. 


Strong partners for 

modern large-press lines 

During the presentation of the new large press, 

SMS Meer also pointed out the importance of 

optimal co-operation with strong and experienced 

partners when it comes to press peripherals. 

Two of these partners, Bosch Rexroth 

and OMAV, provided an insight into their 

specific contributions. 

Bosch Rexroth is responsible for the press’s 

hydraulic drive, which is of particular importance 

in view of the enormous extrusion load 

as well as the required accuracy and efficiency 

when operating the press. The modularly designed 

hydraulic unit is positioned next to the 

press and comprises 12 main pumps, each with 

a power rating of 200 kW and delivery volume 

of 515 l/min, and an operating pressure of 

310 bar. With a volume of 52,000 litres, the 

hydraulic tank is particularly imposing. 

The equipment upstream and downstream 

of the extrusion press is supplied by the Italian 

company OMAV as part of a contract agreed 

directly with the client but executed in close 

co-operation with SMS Meer. OMAV was able 

to point to numerous references for large-press 

extrusion plants. It made particular mention 

of its direct rack and pinion drive that allows 

the motor to move with the puller. This drive 

is very energy efficient, precise and prevents 

damage to the profile surface; the company 

has already used it in over 50 extrusion plants 

since 2002. The pullers and cooling zones are 

designed in such a way that during the cooling 

process the puller can be driven through the 

cooling zone right up to the press run-out. This 

results in a noticeable improvement in yield 

as a result of the shorter lengths of scrap. 

Double blade cold saws, which are finishing 

saws that have two saw blades arranged one 

upon the other, are another speciality from 

OMAV. It is generally known that an extrusion 

plant does not only produce profiles with 

the maximum possible height but also a large 

number of smaller profile sizes; the saw can be 

operated as required, either with two blades 

for large profiles or a single blade for smaller 

profiles. A smaller saw blade diameter results 

in a smaller kerf width and ultimately in lower 

metal losses during sawing and a reduced 

power requirement. 

Author 

Dipl.-Ing. Bernhard Rieth is a marketing specialist 

and freelance technical journalist. As proprietor of 

Marketing Xpertise Rieth in Meerbusch, Germany, 

he advises equipment partners of the NF metals 

semis industry on marketing-related matters. 

400 Strangpressen, die das Unternehmen in 

den letzten 30 Jahren gebaut hat, rund 80 Prozent 

in diesem Segment betrieben. 

Starke Partner für eine 

moderne Großpressenlinie 

Im Rahmen der Präsentation der neuen Großpresse 

wies SMS Meer auch auf die Bedeu- 

SPECIAL CHINA 

fahrende Motoren als „rack and pinion drive“ 

hin. Diesen sehr energiesparenden, präzisen 

und die Profiloberfläche schonenden Antrieb 

verwendet das Unternehmen seit 2002 bereits 

in über 50 Strangpressanlagen. Die Puller und 

die Kühlstrecken sind so konstruiert, dass die 

Puller während des Kühlens durch die Kühlzonen 

bis direkt an den Pressenauslauf heranfahren. 

Das Ergebnis ist eine spürbare Ver- 

Die steigende Nachfrage nach größeren und schwereren Profilen führt zu Strangpressen mit immer 

höheren Presskräften 

Demand for wider, longer, heavier sections results in bigger extrusion presses 

tung der optimalen Zusammenarbeit im Pressenumfeld 

mit starken und erfahrenen Partnern 

hin. Zwei dieser Partner, die Firmen 

Bosch Rexroth und OMAV gaben einen Einblick 

in Besonderheiten ihres Lieferanteils. 

Bosch Rexroth zeichnet für den hydraulischen 

Antrieb der Presse verantwortlich, 

dem angesichts der enormen Presskraft, aber 

auch der geforderten Genauigkeit und Effizienz 

des Pressenbetriebes eine hohe Bedeutung 

zukommt. Die neben der Presse in Modulbauweise 

aufgebaute Hydraulikanlage umfasst 

12 Hauptpumpen mit einer Antriebsleistung 

von jeweils 200 kW und einem Fördervolumen 

von 515 l/min bei einem Betriebsdruck 

von 310 bar. Imposant wirkt der Hydraulik- 

tank mit seinen Volumen von 52.000 Litern. 

Die Einrichtungen vor und hinter der 

Strangpresse werden von OMAV im Rahmen 

eines direkten Kundenvertrags, aber in enger 

Abstimmung mit SMS Meer geliefert. Die italienische 

Firma konnte in diesem Zusammenhang 

auf zahlreiche Referenzen bei Großpressenanlagen 

verweisen. OMAV wies speziell 

auf den Direktantrieb der Puller durch mit- 

besserung der Ausbringung durch verkürzte 

Schrottlängen. 

Ein weiteres Highlight von OMAV sind die 

„double blade cold saws“, das sind mit zwei 

übereinander angeordneten Sägeblättern bestückte 

Fertigsägen. Da bei einer Strangpressanlage 

bekanntlich nicht nur die maximal 

mögliche Profilhöhe erzeugt wird, sondern 

auch eine Vielzahl kleinerer Profilgrößen, 

kann die Säge wahlweise bei großen Profilen 

mit zwei, oder bei kleineren Profilen mit 

nur einem Sägeblatt betrieben werden. Ein 

kleinerer Sägeblatt-Durchmesser führt zu einer 

geringeren Einschnittbreite und damit zu 

geringeren Zerspanungsverlusten sowie zu 

einer geringeren Antriebsleistung. 

ALUMINIUM · 6/2011 35 

Autor 

Dipl.-Ing. Bernhard Rieth ist Marketingspezialist 

und freier Fachjournalist. Als Inhaber der Marketing 

Xpertise Rieth in Meerbusch berät er Ausrüstungspartner 

der NE-Metall-Halbzeugindustrie in Marketingfragen.

SPECIAL CHINA 

Henan Zhongfu Industrial 

Chinese company reports good experience with current-switching device 

Pots can be turned on or off without 

interrupting power to whole potline 

Stopping or starting up a single electrolysis 

cell in a primary aluminium smelter 

without interrupting the power supply to 

the other cells in the potline is like replacing 

a carriage of an express train while 

the train is still travelling at high speed. 

When an individual electrolysis cell needs 

to be started up, shut down or taken off 

load for maintenance, the traditional approach 

has been to switch off power to 

the whole potline. Cell technology, developed 

by China’s Zhengzhou Zhongshi 

Cell Technology Co. Ltd, has made it 

possible to take reduction cells off load 

or start them up without interrupting the 

power supply to the rest of the potline. 

Zhengzhou Zhongshi is an integrated company 

covering research and development, design, 

production, sales and technical service. Its aim 

is to develop and use advanced technologies 

Industrial application of a Cell Switch equipment at a smelter 

and products in power generation, aluminium 

electrolysis and the graphite industry, covering 

four major areas: industrial design, electrical 

automation, industrial furnaces for aluminium 

and new aluminium materials. At present, and 

against the background of an impending energy 

crisis, increasingly more attention is being 

paid to saving energy, especially in the energyintensive 

aluminium industry. It is therefore 

quite fitting that the company’s debut series 

product, Cell Switch, is an energy-efficient 

technology. 

Cell technology, developed by starting up 

or stopping individual pots without interrupting 

the power supply to the rest of the potline 

and the company’s cell switching device are 

both covered by completely separate patents 

and conform to international standards. The 

technology has been approved by the Identification 

Expert Group of the China Nonferrous 

Metals Industry Association (CNIA), the 

Development and Reform Committee, and the 

Science and Technology Bureau. 

Cell Technology reduces the strength of 

magnetic fields in the areas concerned, thus enabling 

the current balance of 300 kA aluminium 

pots to be adjusted in this way for the first time. 

It utilises a separately developed multipoint 

shunt, a synchronous-running switching block 

device (Cell Switch) and a variable resistance 

shunting device (Cell Divider). The system is 

easy to operate and can effectively reduce 

shock to the regulating unit and electrical net, 

thus ensuring safe and reliable operation. The 

technology has also showed great benefits by 

lengthening cell life, increasing energy efficiency, 

and 

reducing 

the anode 

effect and 

its environmental 

impact. By 

adopting 

large-currentdynamic 

transfer 

for the first 

time, the 

switching 

device enablesoperators 

to stop 

and start 

electrolysis cells in large-scale aluminium potlines 

without interrupting the whole current. 

By creatively applying the theory of current 

and energy transfer, the cell switching device 

has been highly successful in taking pots into 

and out of service at full potline current. 

It can be used to start up or shut down 

aluminium reduction cells easily and safely in 

30 minutes. The procedure is easy to understand 

and operate. The Cell Switch is first connected 

and the short block de-energized. Then 

the switching device is turned off. The final 

step is to disconnect the device and remove it. 

The reverse procedure is used in an analogous 

manner to shut down a cell. 

The Cell Switch is used in different industries, 

including aluminium electrolysis (A series), 

copper electrolysis (C series), magnesium 

electrolysis (M series) and other electrolysis 

processes. Different types of switch can be 

supplied, e.g. WDD or LDD types, depending 

on the customer’s specific requirements such 

as cell construction, bus bar structure, shortcircuit 

interface and site arrangement. The Cell 

Switch can be used with various shapes and 

type of electrolytic cell, both in old or new 

smelters. 

The Cell Switch has received many approvals 

and awards since 2006: these include the 

Hi-Tech Product Certification and first prize 

in the CNMIA Science and Technology Award 

competition. It has been also listed in the first 

edition of the NDRC Key Energy-Saving Product 

Catalogue and won the 2011 Gold Award 

for a Chinese-invented patent, the only one 

in the aluminium industry. The Cell Switch 

received European CE certification as early 

as 2008. 

The Cell Switch has attracted considerable 

attention from the aluminium electrolysis industry 

both at home and aboard. The product 

has rapidly become widely used and has gradually 

established itself as an essential energysaving 

device for large aluminium smelters. 

It makes a significant contribution to the 

stability, reliability and economics of the power 

system. By the end of 2010, 59 sets of Cell 

Switch devices had been widely used more 

than 15,000 times in 51 potlines at 36 smelters 

at home and abroad. All of the devices operated 

with 100% reliability to the complete 

satisfaction of the company’s customers. In 

China, the device is used in smelters with a 

total production capability of 6 million tpy that 

account for over 60% of China’s large scale 

aluminium smelting capacity. The company’s 

reference list includes six companies affiliated 

to Chinalco. The device has been used for amperages 

up to 450 kA. 

Cell Technology and the cell switching device 

always focus on helping the smelter operator 

achieve direct economic benefits in the 

form of energy conservation, environmental 

protection and electrical maintenance. 

A detailed description of the Cell Switch 

technology was published in ALUMINIUM 

4/2009, page 77-81. 


SPECIAL CHINA 

First coil rolled at Chalco Ruimin 1+3 hot finishing mill 

Effective project management brings 

a lifetime of benefits for aluminium producers 

Fola Kolade, senior project manager; Ian Postlethwaite, site manager; Siemens VAI 

On 1 April 2011, Siemens VAI successfully 

rolled the first coil at the Ruimin 

1+3 hot finishing mill. The company has 

delivered a number of significant successful 

project references for aluminium hot 

mills, and the tandem finishing mill for 

Chalco Ruimin Co. Ltd will be the latest 

reference to this impressive list. 

The tandem hot aluminium mill is located in 

Fuzhou City, Fujian province, designed to expand 

capacity to over 370,000 tpy at widths 

in excess of 2.2 metres. In addition to the mechanical 

equipment for the 3-stand tandem 

hot mill Siemens VAI supplied all 

automation technology, drive systems 

and the sensors. Benefits for 

the client are the most advanced 

and innovative automation to 

deliver the tightest strip thickness 

and profile tolerances and 

to ensure the highest standards in 

product quality. 

First Coil Data: 

• Entry gauge: 40 mm 

• Exit gauge: 8 mm 

• Width: 1,650 mm 

• Alloy: 3003 

A major factor for the success 

achieved on this project is the result 

of the seamless cooperation 

and the harnessing of advantages 

and experiences of a multinational 

Siemens team from the UK, 

Germany, China, Austria, Poland 

and Ukraine that worked on the 

project. From project management, 

engineering design through to site management, 

Siemens VAI has shown its ability 

and strength in harnessing the synergies across 

the company globally. 

Benefits of effective 

project management 

For aluminium producers, when building or 

modernising a production line, the amount of 

the investment required is not the only issue 

to be considered. Delays to a modernisation or 

the belated commissioning of a new line means 

loss of production and therefore lost revenue. 

So choosing the right partner for a project is as 

important as choosing the right technology. 

Based in Sheffield, UK, the centre of competence 

for aluminium rolling mills worldwide 

is located right at the heart of a vibrant metals 

technology community. 

Mark Chatterton, director of the Siemens 

VAI Aluminium business, sees many advantages 

in leveraging the engineering and project 

management experience gained by both the 

Plate and Aluminium business areas during 

the recent boom years in the metals market. 

“Siemens global project management experi- 

First coil rolled at Chalco Ruimin 

ence is one of our core strengths, which differentiates 

us from our competitors. The company 

is driven to ensure that our project management 

skills are ‘best practice’. As part of the 

company-wide, global project management 

programme, both Plate Mill and Aluminium 

Mill project teams have demonstrated these 

skills through the completion of many complex 

metallurgical infrastructure projects in 

the last five years. Encompassing every aspect 

of a project from planning to installation, a 

partner capable of providing effective management 

from conception to production, ensures 

that an aluminium plant is built on-time, and 

to specification thereby maximising value.” 

Today, Siemens employs more than 15,000 

project managers, all working to the values of 

‘Excellent, Innovative and Responsible’. 

The philosophy is simple; there are clearly 

defined roles and responsibilities for all those 

involved in a project and the programme ensures 

that state-of-the-art processes, methodologies 

and tools are applied in ways appropriate 

to the complexity of the tasks. By 

undertaking both comprehensive training and 

an internal certification process, Siemens also 

ensures that its project managers are trained 

and qualified such that they are able to manage 

a project professionally. Siemens project managers 

are empowered to do the right things, the 

right way and at the right time to achieve the 

project goals. As a global partner, this means 

global uniform procedures, always executed 

in a systematic and professional manner by 

appropriately trained and qualified staff. 

2011 will be an exciting year for the Siemens 

VAI aluminium business, as well as the 

Ruimin hot mill, another high profile project 

will be commissioned and put into full operation. 

� 


Siemens VAI

Visit us: 

Plants for Rolled 

Products 

Düsseldorf, Germany 

28 June - 02 July 2011 

Hall 10 - Stand E 20 

www.otto-junker.de

ECONOMICS 

Dubal minimises environmental impact of operations 

Dubal fume treatment plant 

Dubai Aluminium Company Ltd (Dubal) – 

the wholly state-owned enterprise which 

owns and operates one of the world’s 

largest single-site aluminium smelters – is 

keenly aware of the environmental footprint 

associated with its core activities. 

Accordingly, the company strives continually 

to manage the impact of its operations 

by minimising the use of resources 

and controlling the release of pollutants 

into the environment. The company 

operates a BS EN ISO14001:2004 Environmental 

Management System (EMS), 

which ensures that its operations are not 

only aligned with the most stringent international 

environmental standards, but 

also improve continuously. Several key 

environmental parameters are monitored 

and managed, the most important being 

air emissions and energy consumption, 

along with waste management, water 

consumption, raw materials, and ecology. 

Moreover, the company has spent more 

than AED1 billion (USD272m) on environmental 

projects since 2000 to ensure 

continual improvement in environmental 

protection. 

Air emissions 

Several control systems are in place to minimise 

the air emissions from the company’s 

power generation and smelting processes. For 

instance, there are 15 separate fume treatment 

plants (FTPs) in the operational area of Dubal’s 

Jebel Ali site, which capture and treat 98 

percent of the hydrogen fluoride (HF) emitted 

in the smelting process. Consequently, Dubal’s 

total fluoride emissions dropped by 29 percent 

between 2000 and 2010 (see diagram 1). 

In addition dry, low oxides of nitrogen 

(NO x) combustors have been introduced in all 

Dubal’s large combined cycle machines to reduce 

the concentration of NO x in the ambient 

air. This has resulted in Dubal’s NO x emission 

levels dropping from > 80 ppm to < 20 ppm. 

Dubal power plant 

A similar strategy is being followed on all new 

machines. 

The greenhouse gases (GHGs) emitted by 

Dubal are mainly in the form of carbon monoxide 

(CO), carbon dioxide (CO 2) and perfluorocarbon 

(PFC), the primary contributor 

to greenhouse gas emissions being electricity 

generation. The installation of combined cycle 

power systems at Dubal has enabled marginal 

reductions in CO 2 emissions (through higher 

efficiencies and therefore lower consumption 

of hydrocarbon energy). Reduced use of distillate 

as an energy source has also made a positive 

contribution to NO x and sulphur dioxide 

(SO 2) emissions. One of the latest projects in 

this area is an evaporative cooling (EC) system 

that has been implemented in nine gas 

turbines, resulting in reductions of 350,000 

tonnes of CO 2 and 1,750 tonnes of NO x. 

Importantly, Dubal is committed to achieving 

the International Aluminium Institute (IAI) 

Sustainable Development Initiative (SDI), 

launched in 2003, which comprises voluntary 

environmental performance objectives for 

aluminium smelters. In terms of PFCs, the IAI 

SDI goal is to reduce emissions by 80 percent 

by 2010 and 93 percent by 2020 (from 1990 

levels). By 2010, Dubal had achieved an overall 

drop of 74 percent (compared to 1990), as 

shown in diagram 2. 

Going forward, Dubal has initiated a programme 

to address emission levels and is in 

the process of registering it as a Clean Development 

Mechanism (CDM) project. The programme’s 

primary objective is to decrease the 

number and duration of anode effects (which 

precipitate PFC emissions), thereby minimising 

the generation of CF 4 and C 2F 6 gases. The 

approach will involve changing alumina feed- 


Images: Dubal

ECONOMICS 

Diagram 1: Dubal’s total fluoride emissions per tonne aluminium, 2000 to 2010 

Diagram 2: PFC emissions at Dubal, 1990 to 2010 (CO 2 eq t/tAl) 

ing strategy, which should yield an annual reduction 

in GHG emissions of approx. 20,000 

tonnes of CO 2eq. 

Energy consumption 

Dubal acknowledges that aluminium production 

is a very energy-intensive process, specifically 

in terms of electricity consumption, 

and thus places substantial emphasis on conserving 

energy through efficiency-improving 

measures. By improving current efficiency 

Diagram 3: DC Energy for electrolysis at Dubal, 1990 to 2010 

in the company’s potline operations, a 7.5 

percent reduction has been achieved in the 

energy needed for electrolysis compared to 

1990, resulting in an average smelting energy 

consumption (across all technologies) of 14.82 

MWh/t in 2010 (see diagram 3). Moreover, 

the thermal efficiency of the plant improved 

from 33.8 percent in 1999 to 42.9 percent in 

2010. 

Emphasis is also placed on developing 

energy-efficient technologies. In this regard 

Dubal’s proven, in-house developed DX re- 

duction technology performs among the most 

efficient reduction cell technologies currently 

available. Developed in 2006, DX reduction 

technology has been implemented in a dedicated 

40-cell potline at Dubal’s Jebel Ali Smelter. 

The technology has also been licensed and installed 

in the 75-cell Phase 1 of the Emirates 

Aluminium Co. Ltd (Emal) green-field smelter 

development in Abu Dhabi. It offers several 

operating benefits: 

• an energy-efficient design that enables 

specific energy consumption of less than 

13.05 kWh/kg aluminium and 

95.7 percent current efficiency, which 

together contribute to energy conservation 

and associated operating cost reductions, 

• reduced environmental impact through 

lower fossil fuel consumption (due to 

enhanced energy-efficiency) and reduced 

carbon consumption (anodes) of less than 

0.408 kg C/kg aluminium, 

• reduced anode effects, resulting in 

reduced PFC emissions of less than 

0.008 CO 2eq/t aluminium – a worldleading 

benchmark. 

Ecology 

Ecologically speaking, the marine environment 

is the most sensitive ecological receptor 

in the vicinity of Dubal’s site. The 20 squarekilometre 

Jebel Ali Wildlife Sanctuary is located 

approx. 7 km from our smelter operations. 

The coral communities in this conservation 

site are considered the most diverse in the 

region and therefore of national ecological 

importance. An Environmental Impact Assessment 

undertaken at Dubal’s operations found 

that the water discharged from the plant (brine 

after desalination) has localised impact and 

will not affect the sanctuary. Dubal nevertheless 

regularly performs marine surveys, monitors 

site effluents, and utilises independent 

technical expertise to ensure that its operations 

have the least possible impact on the environment. 

Likewise, any site expansion plans and 

operational changes undergo thorough environmental 

reviews to comply with local regulations 

and to ensure that our environmental 

impacts are minimised. 

Dubal is also actively pursuing opportunities 

to restore the habitat and create aesthetically 

pleasing boundaries to the site. This includes 

a green belt concept, whereby a vegetated 

buffer zone around the perimeter of our site 

has been developed and serves several purposes. 

The green belt comprises 1,545 specimens 

of a plant species that is fluoride-tolerant, yet 

sensitive to HF emissions, and therefore acts as 


type of ‘early warning system’ on higher than 

expected emission levels. 

Community-orientation 

Dubal extends its environmental protection 

efforts into the community, through collaborative 

participation with non-government organisations, 

schools and environment-focused 

bodies at all levels so as to raise awareness 

of the need to conserve natural resources and 

the environment. Wherever possible, these 

initiatives engage Dubal’s employees, so as to 

cascade key messages into the community. 

For example, Dubal is an active member 

of Emirates Environmental Group (EEG) and 

participates in the annual EEG Can Collection 

Campaign. The company also supports 

other environment-related initiatives, such 

as the annual Clean up the World Campaign, 

hosted by the city of Dubai, as well as the 

annual international Earth Hour campaign 

and the annual international World Environment 

Day. 

In 2010, Dubal launched its first-ever internal 

campaign that combines environmental 

education with facilities that encourage environment-friendly 

behaviour. Known as the 

Green belt around Dubal’s smelter 

Green Life Project, the initiative aims to teach 

employees to ‘Think green, act green’, thereby 

nurturing individual responsibility towards 

protecting the environment and conserving 

ECONOMICS 

distributed to all employees and recycling islands 

(for segregating the types of recyclable 

materials targeted) have been placed strategically 

around Dubal’s Jebel Ali site. 

natural resources. Relevant literature has been �

ECONOMICS 

Aluminium glitters as an investment in the GCC region 

Investments in the GCC (Gulf Cooperation 

Council) aluminium industry are expected 

to reach USD55 billion by 2022, 

driven by new factories and projects, 

according to Ventures Middle East’s April 

2011 GCC Aluminium Industry Report. 

“The GCC region, which largely focuses 

on upstream manufacturing activities, 

currently produces 7% of the world’s 

total primary aluminium supply,” Abu 

Dhabi-based Ventures Middle East says. 

This figure will increase to 10% by 2017 

with the completion of three new smelter 

facilities in Saudi Arabia. 

In 2010, the four main smelting facilities in the 

GCC were: Alba in Bahrain, Dubal in UAE, 

Sohar Aluminium in Oman and Qatalum in 

Qatar. UAE-based Emal started operating in 

2011, while the first of the smelter factories in 

Saudi Arabia (KSA) is scheduled to begin production 

in 2013. Initial investments in KSA’s 

smelter facilities are estimated at USD19.5 

billion. Following the completion of these 

facilities, the GCC region’s total production 

capacity will increase at a CAGR (Compound 

Annual Growth Rate) of 18% to 8.2 million 

metric tonnes (MT) in 2017 from 2.2 million 

MT in 2009. 

Currently, 80% of the GCC’s primary aluminium 

output is exported as billets and ingots 

for conversion into finished products outside 

the GCC. However, the region has started to 

shift away from primary production, similar 

to the trend that is occurring in China’s aluminium 

industry. Meanwhile, the demand for 

fabricated aluminium products is rising in the 

local markets across the GCC region as a result 

of an increase in the number of building 

construction projects, which are being undertaken 

in response to the growing population. 

In turn, this is creating a multitude of investment 

opportunities in the secondary production 

market. Casting, rolling and recycling are 

among the industry opportunities in the GCC’s 

secondary production market. 

“The GCC’s demand for fabricated aluminium 

is primarily being driven by the 

growth of the building construction sector,” 

says Ventures Middle East. “The demand for 

extruded aluminium products in the GCC region 

is expected to increase at a CAGR of 8% 

to 394,368 MT in 2015 from 264,974 MT in 

2010.” With CAGR of greater than 6%, Qatar, 

UAE and the KSA have the highest growth 

rates within the GCC’s extruded aluminium 

market. The KSA, followed by UAE, are the 

largest contributors to the GCC’s overall demand 

for extruded aluminium products (2010 

to 2015) by 45% and 28%, respectively. 

Meanwhile, aluminium has started to replace 

traditionally used materials, such as 

plaster, building stone, Glass-Reinforced Concrete 

(GRC) and precast concrete, becoming 

the preferred construction material (e. g. cladding) 

for new high-rise properties throughout 

the GCC. “The demand for fabricated aluminium 

products in 

the building and 

construction sector 

is expected 

to increase at a 

CAGR of 9%, 

reaching USD3 

billion in 2015 

from USD1.9 

billion in 2010,” 

Ventures Middle 

East says. 

The total value 

of all building 

and construction projects between 2010 and 

2015 (excluding those on hold and infrastructure 

projects) across the GCC are estimated 

at USD425 billion. The main segments 

are mixed-use and residential developments. 

The demand for primary and secondary 

aluminium production can also be found within 

the transportation sector. As the population 

grows, so too does the demand for automobiles. 

In recent years, automobile manufacturers 

have taken a preference to cast aluminium 

as its lighter weight contributes to improved 

fuel economy and reduced emissions. In ad- 

Ventures Middle East’s 169-page ‘GCC Aluminium 

Industry Report: April 2011’ provides a review of 

global and GCC aluminium production (upstream 

and downstream) trends, GCC aluminium industry, 

market overview and five-year forecasts, 

recent industry activity and upstream and downstream 

manufacturer profiles and respective 

production capacities and expansion plans. 

The study provides a detailed demand and 

import/export analysis for extruded and fabricated 

aluminium products within key markets such 

as the building and construction sector (comprising 

curtain walls, cladding, windows, doors, etc.) 

for Saudi Arabia, United Arab Emirates, Kuwait, 

Bahrain, Oman and Qatar. 

dition, there is also increased demand for 

rolled aluminium for food and medical packaging. 

Currently, the GCC is a net importer 

of rolled aluminium products, which further 

supports the fact there is a local market need 

for aluminium rolling and the supply of rolled 

aluminium products. 

Adding to the attractiveness of the GCC 

region’s aluminium industry as an investment 

opportunity are the local government’s longer- 

term initiatives that support the growth of each 

market’s manufacturing sector. These initiatives 

derive from the overarching goal of the 

GCC countries to decrease dependence on oil 

and gas sector revenues by increased investments 

in non-oil and gas industry sectors such 

as manufacturing, which includes the aluminium 

industry. Because these economic plans 

are longer-term with some country’s plans running 

through to 2030, increased government 

spending in the aluminium industry will likely 

continue and maintain the overall growth rates 

within the GCC region’s aluminium industry. 

GCC Aluminium Industry Report: April 2011 

Also highlighted are aluminium industry opportunities 

(casting, rolling) and a detailed overview 

of the sectors (transport, packaging) in which 

these opportunities can be found. The last section 

of the report provides an overview of the 

GCC’s industry regulations and the types of incentives 

offered by each country’s government. 

For more information, visit: www.venturesme.com/contents.php?contents=83. 

The price of 

the GCC Aluminium Industry Report is USD2,000. 

To purchase the full report, contact: Mrs Tyfenn 

Le Guennec, Email: tyfenn@ventures-me.com, 

Tel: +971 2 6222 455 ext 106. 

ME0925 – mention this code to get 25% discount 

on the purchase of the report. 


Venture Middle East

Aluminium recycling industry clearly recovering 

The economic development of the aluminium 

recycling industry turned out 

better last year than had been expected. 

In Germany, the production of recycled 

aluminium in the form of casting alloys 

and deoxidation aluminium during 2010 

amounted to 611,139 tonnes, an increase 

of 8.8 percent compared with the previous 

year. For the current year of 2011 

the sector is confident that it will be able 

to maintain the growth of 2010. Roland 

Leder, president of the Association of the 

Aluminium Recycling Industry (VAR), 

and Günter Kirchner, managing board 

member of the VAR, anticipate a production 

increase of five to seven percent in 

2011. 

The demand for casting alloys will increase 

further mainly due to the excellent trade position 

of the automobile industry. As before, 

the automobile industry remains the most important 

customer for aluminium castings. Approximately 

80 percent of casting alloys go to 

that sector. Typical applications are cylinder 

heads, engine blocks or transmission housings, 

but castings are also increasingly used in large 

structural components and auto body applications. 

At present such components are often 

still produced from so-termed primary alloys, 

but the representatives of the sector expect 

that in the foreseeable future sufficient suitable 

scrap will be available to produce them 

from recycled aluminium as well. 

More and more aluminium scrap is being 

taken up for the production of wrought alloys 

in the form of extrusion billets and rolling 

slabs. Besides recycled scrap of the type reprocessed 

by semis manufacturers themselves, 

scrap aluminium is increasingly used for making 

wrought alloys. In Germany 14 companies 

at 21 production sites are producing casting 

alloys and deoxidation aluminium (Refiners), 

while 21 companies are using aluminium 

scrap to make rolling slabs and extrusion billets 

(Remelters). The member-companies of 

the VAR represent over four-fifths of casting 

production in Germany. 

Roland Leder, who is also the managing 

director of Aleris Recycling (German Works) 

GmbH, made it clear to journalists in Düsseldorf 

that the recycling of aluminium makes an 

important contribution to raw material supply 

for industries located in Germany and Europe. 

This is all the more so since energy, in particular 

electric power, is expensive in Europe 

and the production of primary aluminium by 

Development of the production of 

aluminium casting alloys in Europe (since 2005 EU27) 

electrolysis in the region has fallen off. “The 

aluminium recycling industry plays a key role 

in making use of this source of raw material. 

60 percent of the aluminium produced in Germany 

is recovered from scrap. In Europe as a 

whole the figure is around 50 percent,” he says. 

In view of the prospect of long-term rises 

in energy costs, recycled aluminium can make 

the most of its strengths. This is because pro- 

ECONOMICS 

What the graph shows: until 2007 production increased steadily. In 2010 the sector recovered from the 

economic crisis of 2008/09. The leading industry is in Germany, followed by Italy, while the UK and France 

have become less important. The graph does not show that Poland, with an annual production of 250,000 

tonnes, has developed into a ‘shooting star’ of the aluminium recycling industry. Images: VAR 

ducing high-grade aluminium alloys from 

scrap material demands only about five percent 

of the energy required for primary metal 

production. Accordingly, the secondary melting 

industry views the current debate in Germany 

about the swift abandonment of nuclear 

power production, with relative equanimity. 

Ultimately, the industry’s remelting furnaces 

will mainly be gas fired. 

� 

Proportions of the production of primary and 

recycled aluminium in total aluminium production 

What the graph shows: in the coming 20 years the recycling proportion will not increase significantly, but 

the absolute quantity of recycled aluminium will rise 


ECONOMICS 

Mr Leder has mixed feelings when the ecological 

advantages of recycled aluminium are 

used to brand aluminium-containing products 

as particularly environmentally friendly. “This 

in itself encouraging situation could, however, 

become a problem if more and more producers 

want to use recycled aluminium. Even if 

100% aluminium recovery were achieved, 

on a worldwide basis only about 38 percent 

of aluminium needs could be covered by the 

recycled metal. So from our point of view it 

is ecologically not so important how much recycled 

aluminium is contained in a product, 

but rather the extent to which aluminium is 

actually recycled,” he stresses. 

The flow of scrap out of 

Europe has hardly slowed 

The basis of recycling is scrap as a raw material, 

and securing scrap supplies is therefore 

a major concern of the industry. Against that 

background the VAR keeps a close watch on 

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Aluminium exports from the EU to PR China 

(incl. Hong Kong) and India 

China and India remain the largest customers for aluminium scrap worldwide. For China, in view of the 

energy shortage in the country, scrap imports are very important, since “importing scrap is equivalent to 

importing energy,” as Günter Kirchner has made clear. 

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scrap exports to Asia. The sector noted with satisfaction that in 

2010 almost ten percent less aluminium scrap had been shipped 

out of Europe compared with the previous year (mainly to 

Asia). Yet the EU still gave up 1,009,328 tonnes, 124,024 of 

them from Germany. Concrete supply problems did not arise, 

but they cannot be excluded in the longer term, according to Mr 

Leder. As before China has ambitious recycling targets, which 

in the coming years too can only be achieved by importing 

aluminium scrap, he says. Since 2002 6.6 million tonnes of aluminium 

scrap have been exported from the EU. This compares 

with imports of 2.6 million tonnes, so there is a shortfall of 4.0 

million tonnes on balance. “This haemorrhage of raw materials 

has left its mark,” he says. The country most affected was Great 

Britain, where smelters have been compelled to suspend operations 

because of the over-proportional scrap outflow. 

Over the past twelve months the price of casting alloys has 

risen steadily. The rates for aluminium alloy contracts at the 

London Metal Exchange, quoted in dollars and converted to 

euros, rose from 1,352 to 1,820 euros per tonne. Even though 

the LME rates serve only as reference values, the trend is clearly 

recognisable. According to Mr Leder, whether the trend will 

continue cannot be predicted from today’s point of view. From 

Germany’s standpoint, although the general conditions are 

right, at the global level there are too many market uncertainties 

to permit any trustworthy forecasts. 

High capacity utilisation 

Despite the current good conditions of the aluminium recycling 

industry – the capacity utilisation of VAR member companies 

is in no case less than 90 percent and in some cases even close 

to 95 percent – Mr Leder points out that “in the crisis years 

2008/09 and even after, a structural cleansing in the form of 

insolvencies and plant closures took place. This involved capacities 

amounting to about 170,000 tonnes. Meanwhile, 85,000 


tonnes have finally disappeared from the market. 

The remainder could still be reactivated. 

However, from today’s standpoint this is not 

very likely. “It will still be some years before 

Aluminium scrap balance of the EU 

we see a repeat of the record production of 

857,619 tonnes in 2007.” 

The industry is keeping a close watch on 

the efforts by the EU Commission and the Eu- 

Since 2002 more aluminium scrap has been flowing out of Europe than has been coming back into the 

region. Europe is a net exporter of aluminium scrap. Since 2005 the difference has amounted to several 

hundred thousand tonnes a year. The slight downturn in 2010 compared with 2009 does not change the 

fact that in 2010 Europe showed the second-highest scrap outflow of any. 

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ECONOMICS 

ropean Parliament to improve the efficiency 

of the way resources are treated. The aims of 

various programmes also include recovering 

more raw material by recycling. Whether this 

will increase the yield of aluminium scrap, cannot 

at present be foreseen. “One can assume 

that owing to its high value, aluminium scrap 

will be recovered whenever this can be done 

economically. With improved collection and 

sorting methods the recycling rate could still 

be increased, although expectations should not 

be set too high,” said Mr Leder. Aluminium in 

the transport and building sectors is already 

collected and recycled to the extent of approximately 

95 percent at the end of its useful life. 

For other material flows, including aluminium 

packaging, there is still potential for improvement. 

“Despite everything we should remain 

realistic. Even with a recycling rate of 100 

percent only about 40 percent of aluminium 

needs could be covered. This will remain the 

case for as long as the use of aluminium increases.” 

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ECONOMICS 

Swiss aluminium industry 

Production again at record level but 

exchange rate depressed earnings in 2010 

Although the Swiss aluminium industry 

managed to achieve a turnaround last 

year and emerge from the trough caused 

by the financial and economic crisis, the 

weakness of the euro reduced operating 

profits by up to 16%. The continuing 

strength of the Swiss franc steadily weakened 

the international competitiveness of 

the export sector, where up 

to 80% of business is with 

the euro zone. “By means of 

innovative product development 

and a high degree of 

adaptability to the needs of 

user markets by means of 

flexible production management 

and inventory control, 

the Swiss aluminium industry 

achieved production levels 

in 2010 that almost reached 

the record levels of 2007,” 

explained Markus Tavernier, 

president of the Swiss Aluminium 

Association speaking 

to journalists in Zurich. 

Total production at the Swiss 

rolling mills and extrusion plants 

recovered 26% compared with 

their 2009 level to 171,200 tonnes. Domestic 

aluminium consumption in Switzerland 

recorded growth of 14% to 190.800 tonnes, 

which is equivalent to a per capita consumption 

of 24.5 kg. Swiss light-alloy foundries 

processed 20,400 tonnes (+39.6%), whereby 

two-thirds of this went into die-castings. 

Following the drastic slump in demand as a 

result of the crisis, the most important markets 

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for semi-finished aluminium products like the 

automobile, transport, mechanical engineering 

and capital equipment sectors were again 

active: demand in these sectors rose by 50 to 

70%. As Alfred Lichtensteiger, CEO of DGS 

Druckguss Systeme AG, pointed out, the car 

industry in particular was working flat out, 

“partly in three shifts and at the weekend”. The 

reason: because of the discussion on climate 

change, “ever lighter components made from 

aluminium and magnesium are being demanded 

in all vehicle categories in the car industry”. 

Alex Kummer, managing director of Aluminium 

Laufen AG, reported high demand 

for forging stock, “as used, for example, for 

the wishbone”. Roland Gloor, CEO of Alu 

Menziken Extrusion AG, pointed to aircraft 

construction and mechanical engineering, 

which placed heavy demands on innovative 

metallurgical and logistical developments by 

the company. René Gentinetta, managing director 

of Novelis Switzerland AG, pointed to 

the ‘Fusion’ special alloy for car doors, which 

was a major highlight for the sector in 2010. 

With the exception of the railway sector, 

the whole transportation sector including 

commercial vehicles, ships and aircraft, again 

reported growth. As Hubert Zimmermann, 

managing director responsible for large profiles 

at Alcan Aluminium Valais SA, said, in 

the railway sector “there was still an absence 

of government contracts in 2010 because European 

countries were financially stricken”. 

Ruedi Wunderlin, chairman of the supervisory 

board of BWB-Holding AG, reported that in 

his company demand for anodised aluminium 

from the mechanical engineering sector had 

recovered, with growth of over 20%. There 

were equally positive developments in the energy 

sector, with aluminium components being 

used for gas turbines as well as in hydro, wind 

and solar power plants. 

Demand for aluminium 

products in the 

medical sector and for 

use in the food industry 

continued to be strong. 

In the packaging sector, 

the trend towards 

convenience foods and 

single-portion packs is 

gaining more and more 

momentum. “For this, 

aluminium packaging 

offers solutions that are 

innovative, lightweight 

and hygienic into the 

bargain,” explained 

Jürgen Schwarz, managing 

director of Amcor 

Flexibles Rorschach 

AG. 

Order intake in the building sector in 2010 

was also pleasing. “Noteworthy here are above 

all innovations for aluminium windows and 

façades for passive houses and minimum energy 

buildings, with which Swiss manufacturers 

have achieved a leading position, capturing numerous 

awards in these markets of the future,” 

explained Marcel Menet, managing director of 

the Swiss Aluminium Association. 

The recycling of used aluminium packaging, 

which was already at a high level in Switzerland 

in any case, improved still further: 

“91% of all beverage cans are recycled. For 

aluminium pet food trays the collection rate 

is 80% and for aluminium tubes we have already 

reached 60%. In the building and transport 

sectors and mechanical engineering, the 

recycling rate has been over 90% for a long 

time,” explained Mr Tavernier. The readiness 

of the Swiss public in general to participate in 

recycling is exemplary. Besides the established 

collection points in local communities and 

towns, the newly introduced free collection 

service for larger quantities of aluminium cans 

was also well used in 2010. 

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ECONOMICS 

Strong franc 

exerting pressure 

The mainly good news coming from the Swiss 

aluminium sector was severely clouded by the 

weakness of the euro. Specifically, the strong 

Swiss franc already resulted 

in a multi-digit million 

amount being wiped off margins 

in 2010 and up to 16% 

off the bottom line. “Despite 

record quantities being produced, 

it was not possible 

to achieve an adequate return,” 

is how Mr Kummer 

summed up the situation at 

Aluminium Laufen AG. He 

said losses in 2010 and the 

first quarter of 2011 were 

not related to the sector but 

to the exchange rate. 

Mr Gentinetta of Novelis 

Switzerland was of a similar 

opinion: “Almost 100% of 

Novelis Sierre’s production 

is for export to EU countries 

and the resultant pressure 

exerted by the exchange rate was already felt 

very strongly and quickly in 2010.” And Mr 

Gloor from Alu Menziken Extrusion gave a 

sober assessment of the situation: “We have 

increased turnover by 70% and acquired 

about 30% new customers. Nevertheless, the 

bottom line is that there was only lots of work 

but little reward.” 

So far, the Swiss sector has reacted to the 

currency crisis with even tighter cost manage- 

ment, bans on recruitment and longer working 

hours. The full consequences of the negative 

framework conditions are expected in 2011. 

According to Mr Tavernier from the Swiss 

Schweizer Aluminiumindustrie produziert wieder auf Rekordniveau 

Der Schweizer Aluminiumindustrie gelang im 

vergangenen Jahr zwar der Turnaround aus 

der Wirtschaftskrise, doch schmälerte die Euro- 

Schwäche bzw. der starke Franken das Ergebnis 

der zu 80 Prozent in den EU-Raum exportierende 

Branche und belastet deren internationale Wettbewerbsfähigkeit. 

„Mit innovativen Produktentwicklungen 

und einer hohen Anpassungsfähigkeit 

an die Bedürfnisse der Anwendermärkte durch 

ein flexibles Produktions- und Lagermanagement 

erzielte die Schweizer Aluminiumindustrie 2010 

Produktionsmengen, die nahezu wieder dem Rekordergebnis 

2007 entsprechen“, erklärte Markus 

Tavernier, Präsident des Aluminium-Verbandes 

Schweiz vor Journalisten in Zürich. 

Die Gesamtproduktion der Schweizer Walz- 

und Presswerke erhöhte sich gegenüber 2009 auf 

171.200 Tonnen (+26%). Der Aluminiumeinsatz im 

Inland zeigte einen Anstieg auf 190.800 Tonnen 

(+14%). Die Schweizer Leichtmetallgießer verarbeiteten 

20.400 Tonnen (+39,6%), wobei zwei 

Drittel dessen in den Druckguss gehen. 

Wichtige Märkte für Aluminiumhalbzeuge, 

etwa der Automobil- und Transportsektor, haben 

sich wieder deutlich belebt. Die Nachfrage stieg 

in diesen Segmenten um 50 bis 70 Prozent. Vor 

allem für die Automobilindustrie wurde auf Hochtouren 

produziert, die Autohersteller verbauen 

in allen PKW-Klassen mehr und mehr leichte Aluminiumbauteile. 

Auch die Nachfrage im Maschinenbau 

nach anodisierten Aluminiumoberflächen 

hat sich erholt. Ebenso positiv verhielt es sich 

im Energiesektor mit Aluminiumbauteilen für 

Gasturbinen sowie Wasser-, Wind- und Solarkraftanlagen. 

Bei Verpackungen zieht der Trend zu 

Convenience-Produkten für Lebensmittel und zu 

Einzeldosier-Verpackungen mehr und mehr an. 

Aluminiumverpackungen bieten hier innovative, 

leichte und dazu hygienische Lösungen. Erfreulich 

auch die Auftragslage 2010 in der Baubranche. 

„Bemerkenswert sind hier vor allem die Innovationen 

bei Aluminiumfenstern und -fassaden für 

Passivhäuser und „Minergie“(Minimum Energy)- 

Bauten, mit denen die Schweizer Hersteller eine 

führende Position mit zahlreichen Auszeichnungen 

in diesen Zukunftsmärkten eroberten“, 

Aluminium Association, discussions about 

transferring production abroad, with resultant 

job losses in Switzerland, are thus in full swing 

among member companies, too. 

Instead of making eye-catching demands 

on politicians, the sector is depending on helping 

the industry to help itself. 

The Swiss Aluminium 

Association recently instigated 

a meeting with 

representatives of leading 

Swiss associations that act 

on behalf of companies engaged 

in trade and industry 

and together cover some 

500,000 jobs in the metal, 

plastics and packaging industries. 

“Jointly we think 

encouraging innovation 

is the way to stabilise our 

competitiveness because it 

is the most direct approach 

and offers the greatest 

potential. If we remain as 

innovative as possible, the 

discussion on prices will 

take a backseat,” summed 

up the managing director of the association, 

Mr Menet. Accordingly, the association will be 

seeking a dialogue with politicians about new 

forms of support at federal level. � 

erläuterte Marcel Menet, Geschäftsführer des 

Aluminium-Verbandes Schweiz. 

Massiv getrübt werden die überwiegend guten 

Nachrichten aus der Schweizer Branche durch 

den Kursverfall des Euro. Konkret verursachte der 

starke Franken bereits 2010 Margenverluste in 

mehrstelliger Millionenhöhe und ein Minus von 

bis zu 16 Prozent im Resultat. Roland Gloor, CEO 

der Alu Menziken Extrusion AG, stellte ernüchtert 

fest: „Wir haben unseren Absatz um 70 Prozent 

gesteigert und rund 30 Prozent an Neukunden 

gewonnen. Jedoch blieb unterm Strich nur viel 

Arbeit und wenig Brot.“ 

Bislang reagierte die Branche mit einem 

straffen Kostenmanagement, Personalstopps und 

Arbeitszeitverlängerungen auf die Währungskrise. 

Die ganze Tragweite dieser negativen Rahmenbedingungen 

wird für 2011 erwartet. Die Diskussionen 

über Produktionsverlagerungen ins Ausland 

und damit den Verlust von Arbeitsplätzen in der 

Schweiz seien daher auch unter den Mitgliedsfirmen 

in vollem Gang, so Verbandspräsident 

Tavernier. 


Ökosteuer: Den individuellen 

Erstattungsanteil steigern 

Die gesetzlichen Neuregelungen im Strom- und Energiesteuerrecht, 

die Anfang 2011 in Kraft getreten sind, belasten das 

produzierende Gewerbe erheblich. Möglichkeiten zur Erhöhung 

des Erstattungsanteils bleiben allerdings häufig ungenutzt, 

obwohl die öffentlichen Abgaben und Steuern bis zu 

50 Prozent der Gesamtenergiekosten vereinnahmen können. 

Im Rahmen des Haushaltsbegleitgesetzes für 2011 hat der Bundestag 

im Oktober 2010 im Energie- und Stromsteuerrecht weitreichende 

Änderungen beschlossen: Die wichtigste Neuerung im 

Stromsteuergesetz besteht darin, dass das Erlaubnisscheinverfahren 

entfällt. Damit müssen zukünftig alle Unternehmen zunächst den 

vollen Stromsteuersatz in Höhe von 2,05 statt wie bisher 1,23 Cent 

je kWh an ihren Lieferanten entrichten. Um weiterhin Vergünstigungen 

zu erhalten, müssen Unternehmen im Nachhinein Steuererstattungsanträge 

stellen. Die veränderten Erstattungssätze führen 

jedoch per Saldo zu erhöhten Energiekosten. 

Neben dieser verfahrensrechtlichen Änderung wurde auch die 

effektive Ermäßigung für Unternehmen des produzierenden Gewerbes 

um 25 Prozent reduziert: von 8,2 auf 5,13 Euro je MWh. 

Außerdem mindert der Gesetzgeber die Entlastungsmöglichkeiten 

gemäß §54 Energiesteuergesetz von 2,20 auf 1,38 Euro je MWh 

beim Erdgasbezug. Im Rahmen des Spitzenausgleichs gemäß §10 

Stromsteuergesetz und §55 Energiesteuergesetz wurde die Erstattungsgrenze 

von 95 auf 90 Prozent reduziert und die nicht erstattungsfähigen 

Sockelbeträge auf 1.000 Euro (Strom) und 750 Euro 

(Energie) erhöht. Der Sockelbetrag benennt die Grenze, ab der 

eine Ökosteuererstattung überhaupt erst beantragt werden kann. 

Zudem erhöhte sich die Umlage gemäß Erneuerbare-Energien- 

Gesetz (EEG) um 72 Prozent auf nunmehr 3,52 Cent je kWh, da 

immer mehr Strom aus erneuerbaren Energiequellen in die Netze 

eingespeist wird. 

Subventionsmittel werden häufig verschenkt 

Viele Unternehmen nutzen ihre Möglichkeiten zur Steuerentlastung 

nicht vollständig. „Nach unserer Erfahrung beantragen überhaupt 

nur etwa 70 Prozent der berechtigten Unternehmen des produzierenden 

Gewerbes Steuererstattungen. Von diesen 70 Prozent 

sind es nach unserer Schätzung nur 20 Prozent, die das gesamte 

Erstattungsvolumen ausschöpfen“, erläutert Sebastian Igel, Geschäftsführer 

der En-Control, Gesellschaft für Energiecontrolling 

aus Hannover. Die Gründe dafür liegen in den komplexen Erstattungsverfahren, 

die häufig zu Fristversäumnissen führen. Oft sind 

die steuerlichen Berater mit Verbrauchs-, Energie- und Stromsteuer 

nicht ausreichend vertraut und können den Unternehmen nicht die 

notwendige Unterstützung bieten. Oder die geringe Erfahrung mit 

steuerlichen Erstattungsverfahren führt zu der irrigen Annahme, 

die Nutzung der steuerlichen Gestaltungsmöglichkeiten sei grundsätzlich 

missbräuchlich. 

Erstattungsanteil mit Hilfe eines Online-Beraters steigern 

Unterstützung bei der Suche nach erstattungsfähigen Anteilen liefert 

ein Online-Energiesteuer-Berater. Dieser Service ist das Ergebnis 

ALUMINIUM · 6/2011 

WIRTSCHAFT 

www.thebrightworldofmetals.com 

www.gmtn.de 

The Bright 

World 

of Metals. 

Düsseldorf, Germany 

28 June – 02 July 2011 

Ein Termin – vier Ereignisse – ein Standort 

Erleben Sie vier hochkarätige Fachmessen für 

Gießereitechnik, Metallurgie, Thermoprozesstechnik 

und Präzisionsgussprodukte an einem 

Standort und mit einer Eintrittskarte. 

Weltweit die Nr. 1 der Branchen, vielfache 

Synergien, Verbindungen und Vernetzungen 

bei nur einem Messebesuch. 

Herzlich willkommen in Düsseldorf!

Foto: BMU / Bernd Müller W IRTSCHAFT 

einer Kooperation der Energieberatungsgesellschaft 

En-Control und des Braunschweiger 

Ingenieurbüros Energie Revision. Unter 

www.energiesteuer.de leitet die Menüführung 

Energieverbraucher durch den Paragraphendschungel 

und verschafft Unternehmen den 

notwendigen Durchblick: Individuell angepasst 

berücksichtigt das Online-Portal aktuelle 

Energiepolitische Vorfahrt für erneuerbare Energien. Die 

Belastungen aus dem Stromsteuergesetz steigen dabei für 

das produzierende Gewerbe kontinuierlich. Professionelle 

Beratung kann helfen, Potenziale zur Steuerentlastung 

besser zu nutzen. 

und in 2010 geltende Regelungen zur Ökosteuer. 

Die Erstattung für 2010 kann / muss 

bis Ende 2011 bei den zuständigen Hauptzollämtern 

eingereicht werden. Darüber hinaus 

werden vollständig ausgefüllte und amtliche 

Antragsformulare bereit gestellt. „Unser 

vorerst kostenloses Angebot vereinfacht die 

Antragstellung zur Ökosteuer-Rückerstattung 

erheblich und Interessenten können ergänzende 

Beratungsleistungen über Abgaben und 

Steuern beim Energiebezug in Anspruch nehmen 

– vom günstigen Energieeinkauf bis hin 

zu Effizienzmaßnahmen“, beschreibt Jurist 

Igel den Nutzen. „Eine Reihe gemeinsamer 

Projekte hatte gezeigt, dass die gemeinsame 

Arbeit eines auf Energiesteuerrecht spezialisierten 

Rechtsanwalts und eines Wirtschafts- 

Ingenieurs aufgrund der oft technisch-juristischen 

Zusammenhänge Vorteile für die 

Kunden birgt.“ Um dem Beratungsbedarf der 

Kunden nachzukommen, erbringen Wilhelm 

Stock und Sebastian Igel ihre energiesteuer- 

rechtliche Beratungsleistung künftig gemeinsam. 

Steuern sparen mit Contracting 

Der Begriff Contractor bezeichnet hierbei 

einen Nutzenergielieferanten für Kälte, Licht, 

Wärme, Druckluft und mechanische Energie 

(z. B. Lüftung, Pumpen, Förderbänder). 

Die Höhe der im sogenannten Spitzensteuerverfahren 

erzielbaren Rückerstattungen 

ist maßgeblich durch das 

Verhältnis zwischen Personal- und 

Energiekosten bestimmt. Durch die 

Einschaltung eines Nutzenergie-Contractors, 

der für ein Industrieunternehmen 

beispielsweise Wärme und Druckluft 

bereitstellt, können investitionsfrei 

erhebliche Steuerminderungen erzielt 

werden, da dieser mit nur wenigen 

Mitarbeitern Hunderte Gigawattstunden 

Strom und Gas in Nutzenergie umwandelt. 

Der Contractor erhält daher 

die maximal möglichen 90 Prozent der 

Ökosteuer vom zuständigen Hauptzollamt 

erstattet. Diese Rückerstattung 

reicht er abzüglich einer Servicepauschale 

an den Kunden weiter. Das Vertragsverhältnis 

zu dem gegenwärtigen 

Strom-, Öl- oder Gaslieferanten wird 

von dem Konzept nicht berührt. Vertraglich 

wird dem Contractor lediglich 

die Nutzung jener Anlagen übertragen, 

die Nutzenergie liefern. 

En-Control bietet dieses Konzept 

zusammen mit einer umfassenden Energieberatung 

ab einem jährlichen Stromverbrauch 

von fünf Gigawattstunden 

Strom / Gas an. Ziel ist es, mit der eingesparten 

Ökosteuer die Energieeffizienz im Unternehmen 

zu erhöhen und damit den Ausstoß 

klimaschädlichen Kohlendioxids zu mindern. 

Dieses Vorgehen wurde bis Ende 2010 mit Erfolg 

primär für das nicht produzierende Gewerbe 

umgesetzt und kann zumindest bis Ende 

2012 in der jetzigen Form betrieben werden. 

Danach laufen Übergangsvorschriften der Europäischen 

Union aus, die jedoch bisher nicht 

in deutsches Recht umgesetzt wurden. 

Durch das Modell lassen sich darüber 

hinaus auch die zum Jahreswechsel um 72 

Prozent gestiegenen Abgaben gemäß EEG 

mindern: „Wenn an einem Standort mehr 

als zehn Gigawattstunden per annum Strom 

in Nutzenergie umgewandelt werden, kann 

eine Minderung der EEG-Abgabe um circa 

drei Cent je Kilowattstunde erreicht werden,“ 

führt Igel weiter aus. „Auch wenn dies nur für 

Unternehmen in Frage kommt, die weit mehr 

als zehn Gigawattstunden pro Jahr an einem 

Standort verbrauchen und die Einführung 

eines Energiemanagementsystems vorausgesetzt 

wird, bestehen hier nennenswerte Potenziale 

zur Kostenminderung. „Gleichzeitig 

sparen sich unsere Kunden die aufwendigen 

Zertifizierungen im Rahmen der DIN EN 

16001, da nur der Contractor zertifiziert sein 

muss“, so Igel. 

Neben Belastungen auch Chancen 

Die Neuregelungen bedeuten jedoch nicht nur 

höhere Energiekosten, sondern bieten auch 

Chancen. So können bestehende Energielieferverträge 

zugunsten der Kunden nachverhandelt 

werden. Hierbei gelingt es regelmäßig, 

einen Teil der in der Vergangenheit gezahlten 

Beträge zurückzuholen und zukünftige Kosten 

zu mindern. Die Kooperationspartner bieten 

diesen Service für Unternehmen mit jährlichen 

Energiekosten von mindestens 500.000 

Euro auf Basis eines rein erfolgsabhängigen 

Honorarmodells. 

Ein Gewinn für die Umwelt 

En-Control ermöglicht eine Win-Win-Situation 

für alle Beteiligten, denn Contracting 

lohnt sich nicht nur wirtschaftlich, sondern 

dient auch dem Klimaschutz: Der Contractor 

kann Anlagen aufgrund seines Knowhows effektiver 

betreiben oder er berät den Kunden 

bei Investitionen in energieeffiziente Maßnahmen 

– und leistet damit einen wichtigen 

Beitrag zur Minderung klimaschädlicher CO 2- 

Emissionen. Jede eingesparte Kilowattstunde 

reduziert den CO 2-Ausstoß um 636 Gramm. 

Darüber hinaus kann sich der Kunde auf sein 

Kerngeschäft konzentrieren und erhält die 

benötigten Medien geliefert. „Die Bundesregierung 

verschafft Unternehmern per Contracting 

wichtige Finanzhilfen für klimaschonende 

Maßnahmen, allerdings machen viele 

Unternehmen davon noch keinen Gebrauch“, 

beschreibt Igel die Situation. „Unsere Verträge 

sind mit einer Frist von einem Jahr kündbar, 

da wir unsere Kunden durch gute Leistung 

und nicht mit langfristigen Verträgen an uns 

binden möchten. Sämtliche mit der Konzeptumsetzung 

verbundenen Leistungen der En- 

Control werden mit einer sich prozentual an 

der Rückerstattung orientierenden Servicepauschale 

vergütet, sodass unsere Kunden 

wirklich ohne jede Vorleistung das Konzept 

umsetzen können“, beschreibt Geschäftsführer 

Igel die Firmenphilosophie. 

Kontakt: En-Control Gesellschaft für Energie- 

Controlling, Tel: 0511 / 568893-9, Fax: 0511 / 

568893-8, www.oekosteuer.com 


Rene Tillmann / Messe Düsseldorf 

GIFA, METEC, THERMPROCESS, NEWCAST 2011 

Gifa, Metec, Thermprocess und Newcast 2011 

So groß wie nie zuvor 

Alles spricht dafür, dass die Messen Gifa, 

Metec, Thermprocess und Newcast einen 

neuen Ausstellerrekord erzielen werden. 

Vor allem bei der gebuchten Fläche hat 

das Düsseldorfer Metallmessen-Quartett 

deutlich zugelegt, sehr zur Freude von 

Messe-Projektleiter Friedrich-Georg Kehrer: 

„Damit haben wir nicht gerechnet. 

Jeder in unserer Branche dachte, dass die 

Aussteller zwar kommen würden, aber 

mit deutlich kleineren Ständen. Nun zeigt 

uns der Buchungsstand, dass die Messen 

um fast 5.000 Quadratmeter deutlich 

zugelegt haben.“ Bis Ende März wurden 

bereits 77.230 Quadratmeter von den Unternehmen 

gebucht. Die Messe Düsseldorf 

reagierte auf diesen Ansturm und stellte 

mit der Halle 3 eine weitere, größere 

Halle für die Metec zur Verfügung. Auch 

diese Fläche ist inzwischen nahezu ausgebucht. 

Die vier Technologiemessen präsentieren 

sich nun in den Hallen 3 bis 17. 

Der Anmeldestand spiegelt auch die reale 

Situation in der Branche wieder, denn nicht 

alle Unternehmen haben die Krise vollkommen 

unbeschadet überstanden. Gerade auf 

der Gifa macht sich das bemerkbar. Die meisten 

Unternehmen wollen und können zwar 

Flagge auf der Messe zeigen, deshalb liegen 

auch hier die Anmeldezahlen nahezu auf dem 

Niveau der Veranstaltung von 2007, doch gerade 

bei den Maschinen- und Anlagenbauern 

für die Gießereien haben sich krisenbedingt 

einige Firmenfusionen ergeben. Daher ist die 

Gifa, Metec, Thermprocess and Newcast 2011 

Bigger than ever 

There is every indication that the metal 

trade fairs Gifa, Metec, Thermprocess and 

Newcast (28 June to 2 July 2011) will 

be setting a new exhibitor record. There 

has been a particularly large increase in 

the space booked at the Düsseldorf trade 

fairs: while the companies presented 

their products and services on a total of 

72,698 square metres of exhibition space 

in 2007, when the present record was 

set at the top of the economic boom, the 

trend in 2011 is definitely towards larger 

stands. Something that the trade fair 

project director Friedrich-Georg Kehrer 

is very pleased about: “We didn’t expect 

this. Everyone in our industry thought 

that the exhibitors would come, but with 

substantially smaller stands. The bookings 

made to date reveal, however, that 

the trade fairs have grown considerably, 

by almost 5,000 square metres.” 77,230 

square metres have been booked by companies 

in total so far. 

Messe Düsseldorf already responded to exhibitors’ 

requests for larger stand areas a number 

of months ago and made another, larger hall 

(Hall 3) available for Metec – and the space 

there is almost fully booked in the meantime 

as well. The four technology trade fairs are 

now being held in Halls 3 to 17. 

The registration figures reflect the actual 

situation of the industry too. Because not all 

companies have survived the crisis completely 

unscathed and the impact of this is being felt 

at Gifa in particular. Most companies want 

and are in a position to be represented at the 

trade fair, which is also why the registration 

figures here are almost as high as at the previous 

event, but the crisis has led to a number 

of corporate mergers between the manufacturers 

of machines and equipment for foundries 

in particular. The number of exhibitors has 

therefore decreased slightly from 793 in 2007 

to 723 companies now. The exhibitors are not 

willing to compromise on space, however, 

and have booked about 42,000 square metres 

(2007: 43,800) in Halls 10 to 13 and 15 to 

17 on the exhibition site in Düsseldorf, even 

though fewer companies are exhibiting. 

It looks like a new record for both the 

number of exhibitors and the amount of space 

booked will be set at Metec: 18.4 percent more 

companies will be represented, while the stand 

space booked has increased by more than 

34.6 percent. With 437 exhibitors and almost 

20,000 square metres of space, the trade fair 

is bigger than ever before. 

The number of companies registering for 

Thermprocess is considerably higher than in 

2007 too: about 300 exhibitors and more than 

9,500 square metres of space booked are extremely 

impressive figures. The trade fair will 

as a result have more exhibitors this year than 

ever before in its 37-year history. 

The most recent addition to the ‘Bright 

World of Metals’ – Newcast – has also made 

good progress, demonstrating that it now 

holds an established position. It was launched 

in 2003 with 255 exhibitors, whereas about 

300 companies will be presenting their products 

and services to visitors on almost 6,000 

square metres of stand space this year. Newcast 

is the most international event in its industry 

as well: 78 percent of the exhibitors do 

not come from Germany; they come instead 

from the neighbouring European countries 

and from overseas. Brazil, China, India, South 

Africa and the USA are playing particularly 

prominent roles here. 

� 


SPECIAL GIFA, METEC, THERMPROCESS, NEWCAST 2011 

Ausstellerzahl gegenüber 2007 leicht auf 723 

Unternehmen (2007: 793) zurückgegangen. 

Bei der gebuchten Fläche machen die Aussteller 

jedoch keine Kompromisse und belegen 

mit weniger Unternehmen rund 42.000 

Quadratmeter (2007: 43.800) in den Hallen 

10 bis 13 sowie 15 bis 17 des Düsseldorfer 

Messegeländes. 

Für die Metec zeichnet sich ein neuer Rekord 

sowohl auf Aussteller- als auch Flächenseite 

ab: Sie hat um 18,4 Prozent bei den Unternehmen 

und um mehr als 34,6 Prozent bei 

Gifa 2011 in Düsseldorf 

der Ausstellungsfläche zugelegt und präsentiert 

sich mit 437 Ausstellern und fast 20.000 

Quadratmetern größer denn je. 

Auch die Thermprocess hat ihren Anmeldestand 

von 2007 deutlich überschritten und 

steht mit rund 300 Ausstellern und mehr als 

9.500 Quadratmetern gebuchter Fläche auf 

einem sehr soliden Fundament. Damit stellt 

sie in diesem Jahr mehr Aussteller als jemals 

zuvor in ihrer 37-jährigen Messegeschichte. 

Das jüngste Messekind in der „Bright 

World of Metals“, die Newcast, hat eben- 

Casting technology – advances thanks to know-how 

As a manufacturing process fabrication by 

casting still has a great future, since new 

processes and materials are continually 

extending the limits of feasibility. Nowadays, 

flexibility and productivity of the 

casting methods and high casting quality 

are taken for granted without restriction. 

Thus, process reliability and especially environmental 

tolerance are at the focus of 

interest in forward-looking processes. On 

the basis of the process technologies that 

result from this the foundry branch has to 

meet competition against other production 

methods and non-cast products. 

Globally active customers demand from the 

mostly medium-sized foundry companies an 

all-round service – from consultancy up to 

worldwide technical customer servicing. At 

the same time more and more companies are 

developing from partial suppliers to become 

full-service system partners. Holistic solutions 

for production and the plant life-cycle, which 

apply already from a customer’s first inquiry 

or from the first ideas for a new product, have 

meanwhile become and important competition 

factor. 

Besides compliance with continually increasing 

environmental requirement, concepts 

and technologies for increasing customer benefit 

are decisive points for the future of sand 

core production. Against this background in- 

organic binders are more and more coming to 

the attention of the foundry world. The free- 

falls einen großen Sprung gemacht und darf 

sich zu Recht als etabliert bezeichnen. 2003 

mit 255 Unternehmen gestartet, werden sich 

in diesem Jahr rund 300 Aussteller auf fast 

6.000 Quadratmetern Fläche den Besuchern 

präsentieren. Die Newcast ist zudem die internationalste 

Veranstaltung ihrer Branche: 

78 Prozent der Aussteller kommen nicht aus 

Deutschland, sondern aus den europäischen 

Nachbarstaaten und aus Übersee. Brasilien, 

China, Indien, Südafrika und die USA spielen 

hier herausragende Rollen. � 

dom from emissions and odours that characterises 

inorganic binder systems have advantages 

for both people and the environment, 

and make compliance with future environmental 

protection prescriptions much easier. 

However, their technological advantages too 

are notable. Since they allow more complex 

casting geometries at the same time as higher 

temperature stability and dimensional precision 

when casting, they open up quite new possibilities 

for designers. Moreover, the reduction 

of core-gas-related casting defects promises 

higher productivity. Appreciable cost 

savings result from the better core removal 

characteristics when existing core-removal 

techniques are used, and mechanical regeneration 

cuts the cost of old sand disposal. � 



To maximise the potential of inorganic core 

production a number of hurdles have to be 

overcome. Besides a suitable binder system, 

the key to success is adaptation of the machine 

technology and optimally matched core-making 

tools. That these challenges can be met, 

has been demonstrated by innovative German 

automobile companies, whose success 

has provided further stimulus for the trend in 

the branch. 

Since casting processes are very labourintensive, 

it is important to develop systems 

for automating them. In foundries industrial 

robots allow the creation of particularly efficient 

production and manufacturing lines. 

The prerequisite for this, however, is optimum 

interaction between the robots, the software 

and ‘smart’ sensor systems. Greater process 

reliability, increased productivity and maximum 

flexibility are among the results of a 

well-considered automation process. Further 

possibilities for increasing the energy efficiency 

of an automation solution are given 

by the decision for a suitable overall concept, 

by the choice of energy-efficient components 

and by the possibility of temporarily disconnecting 

components not needed at the time. 

For example, if robots are being used their 

paths should be planned in an energy-efficient 

manner, i.e. with maximum acceleration and 

speed only when the cycle time so requires. 

Led by the automobile industry as the 

foundry branch’s most important customer, 

the trend towards lightweight construction 

has encouraged the use of qualitatively better 

cast irons, but also aluminium and magnesium. 

However, the replacement of conventional 

materials can only succeed if the entire 

process chain is adapted to the new materials. 

Thus for example, the manufacturers of 

foundry machines have developed further a 

tried and tested moulding technique to create 

a low-pressure sand casting unit for aluminium. 

Compared with conventional gravity 

diecasting methods this casting technique enables 

a substantially more quiet mould-filling 

process which, moreover, can be influenced 

by the pressure so that considerably smaller 

wall thicknesses can be produced. This in turn 

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provides possibilities for casting process adaptation 

to the respective range of castings and 

for influencing the solidification process. The 

combination of good mechanical properties 

that can be achieved with the low-pressure 

casting process and the design freedom of the 

sand casting process aims at the production 

of complex castings which could not be produced 

by gravity diecasting, or not with the 

necessary high quality, and which could not 

be produced economically in the relatively 

small production runs involved 

by pressure diecasting. 

The enormous volumes anticipated 

in the coming years 

in the powertrain and structural 

component sectors demand 

corresponding developments 

and technologies in pressure 

diecasting as well. The related 

advances in pressure diecasting 

machines and equipment 

have been huge and in particular 

enable precise process 

control of process sequences 

and parameters with optimum 

process control throughout 

the production chain, from 

the metal melt all the way to 

the finished component. This 

involves a high level of automation, 

control and regulation. 

Simplicity in the operation of 



the entire plant and the associated diagnostic 

and servicing support are indispensable. 

In the volume segment of small and very 

small parts, maximum productivity is ensured 

by virtue of the cycle time. In this context a 

mould technology is used, which works with 

very large numbers of mould cavities and 

integrated injection technology. In the machine 

sequence the movements of the axes 

are synchronised with one another and the 

casting process is monitored visually for proc- 

ess control purposes. Compared with previous 

technologies and depending on the parts 

concerned, production increases of up to 100 

percent can be achieved. A major potential 

for energy saving in pressure diecasting is 

thermal process control, i. e. in the area of 

furnace technology, melt handling and tempering 

of the plant. This is recognised by the 

industry and results, for example, in new and 

process-adapted heating systems, as for the 

nozzles and casting container system. 

Magma presents the economic benefits 

of casting process simulation 

Magma GmbH will present its new software 

generation Magma 5 for casting 

process simulation at the Gifa. It can 

be used for optimisation at all stages of 

casting manufacturing to contribute to 

foundry profitability. The newest version 

Magma 5 5.2 with extended capabilities 

for all cast materials and processes. 

Moreover, Magma will introduce its new 

software Magma C+M for the simulation 

of the core production processes and 

provide a view into the future of autono- 

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The integration of computer-supported design 

methods, stress analyses by means of FEM, 

simulations of casting processes and Rapid 

Prototyping is ensured in development processes 

from an early stage. Furthermore, the 

most important customer segments demand 

digital product models. Thanks to still more 

complete linking of design and production by 

means of CAM/CNC files based on design databases, 

future foundry technology processes 

will become even more flexible. � 

mous optimisation of casting processes. 

Additionally, Magma is participating in the 

initiative ‘ecoMetals’ from the Messe Düsseldorf. 

Magma will demonstrate, using practical 

examples, how the consequent application of 


Images: Magma 


The process orientation of Magma 5 

illustrated using die casting 

casting process simulation considerably increases 

a foundry’s energy and resource efficiency. 

Magma 5 - optimised reality 

Magma 5 5.2 introduces several new simulation 

capabilities: new process modes for permanent 

mould, low pressure sand and low pressure 

die casting, as well both hot-chamber and 

cold-chamber die casting allow for detailed 

process-specific definitions. The software also 

supports process design by controlling process 

parameters during a simulation run. For gravity 

casters, process modules for ‘Disamatic’ 

and investment casting are now available. 

At Gifa, Magma will also present its newest 

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developments for the quantitative prediction 

of as-cast and heat treated local microstructures 

and properties in aluminium, iron and 

steel castings. Magma5 simulates sand and 

reoxidation inclusions during mould filling 

and predicts defects related to moulding materials. 

Magmanonferrous calculates the final 

microstructure and mechanical properties for 

aluminium alloys considering the metallurgy, 

inoculation, and hydrogen content of the melt. 

Magmairon predicts local microstructures for 

iron materials from graphite growth through 

to the distribution of phases making up the 

matrix. Magmasteel calculates macrosegregation 

in steel castings and the local microstructure 

resulting from heat treatment. 

The stress module Magmastress for the first 

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time offers the 

option to calculate 

thermally 

induced casting 

stresses in permanent 

moulds 

for all manufacturing 

steps, 

including heat 

treatment and 

finishing, in order 

to predict 

casting crack 

problems and 

distortion. The 

simulated distortion 

results 

can be evalu- 

ated just as on a coordinate measuring machine 

and compared directly with real measurements. 

For the first time, the new module 

Magmadielife facilitates the evaluation of the 

effects of tooling design and thermal stresses 

on the durability of permanent moulds. 

Magma Core+Mould: 

transparency in core production 

With Magma C+M, Magma introduces an integrated 

tool for the simulation of core production 

processes. The tool simulates core shooting, 

blowing and hardening of organic and 

inorganic cores. Processes where binder hardening 

is driven by a catalyst gas as well as core 

production with tempered core boxes are supported. 

Magma C+M considers all aspects of 

core production starting from the core shooter, 

in order to calculate the flow of the air-sand 

mixture based on the real shot parameters. 

An integrated database provides the ability to 

specify the characteristics 

of the 

With 

Magma 

C+M, the simulation 

of the 

core shooting process is possible for complex tools, 

shown here for three cores including blow tubes in 

a single core box 

sand and the binder system as well as core 

box vents and blow tubes. The program simulates 

gassing, purging and the curing reaction 

of gas-hardened cores. The design and control 

of core box tempering for heat-cured cores 

(hotbox, croning, inorganic) is effectively 

supported by modelling of heating cartridges 

and oil channels. For inorganic cores, Magma 

C+M calculates the drying of the core in the 

heated core box as well as due to transport 

of water vapour by hot air during gassing. 

Magma C+M takes advantage of all the functionality 

of Magma 5 and is available as an 

add-on module to Magma 5 or as a stand-alone 

product. 

Autonomous optimisation is the future 

With autonomous optimisation, foundry men 

can make use of simulation in order to pursue 

their objectives for quality and costs. Autonomous 

optimisation makes proposals for the 



About software for casting process simulation 

Casting process simulation software considers the 

complete casting process including mould filling, 

solidification and cooling, and provides the 

quantitative prediction of mechanical properties, 

thermally induced casting stresses and the distortion 

of cast components. Simulation accurately 

describes a cast component’s quality up-front 

before production starts, and the casting layout 

can be designed with respect to the required 

component properties. This results in a reduction 

in pre-production sampling, but also the precise 

layout of the complete casting system leads to 

energy, material and tooling savings. 

The range of application of Magma solutions 

comprises all cast alloys, from cast iron to aluminum 

sand casting, permanent mould and die 

casting up to large steel castings. The software 

supports the user in component design, the 

determination of melting practice and casting 

methoding through to mould making, heat treatment, 

and finishing. This saves costs consequently 

along the entire casting manufacturing route. 

ABB – comprehensive portfolio 

for foundry and metal-processing industries 

ABB will be showcasing itself at Gifa 

(Hall 17, Stand D44) and Metec (Hall 

4, Stand C14/D20). The company will 

present the foundry and metal-processing 

industries with its comprehensive electrical 

and automation portfolio. 

Under the motto ‘The power of integration’, 

the stand in Hall 4 will offer international visitors 

numerous products and system solutions 

for the metal-processing industry. Integration 

will span from electrical equipment for 

metallurgical facilities with low- and medium 

voltage switchgear, over motors and drives, to 

process control systems, all the way to force 

measurement and crane technology. System 

solutions, energy efficiency consulting and 

classic service products round off the portfolio. 

All over the world, customers from primary 

metal production operating profile, wire and 

Please visit us at GIFA: 

hall 17, stand A26 

Force Control Machining – the innovative solution 

for robot based machining of any workpieces, 

from programming to adaptation 

Logistics for the metal and foundry industries 

right casting layout or the optimum process 

parameters. The virtual test foundry in the 

computer enables variation of parameters 

and systematic examination of influencing 

variables leading up to the optimum configuration. 

Based on the fundamental physics embedded 

in Magma5 , the program finds the best 

possible dimensions and positions of ingates, 

as well as the location of feeders and chills 

including their optimum size. Using industrial 

examples, Magma will present state-of-the-art 

capabilities and provide a view into the future 

of optimisation. 

Magma is an exhibitor at Gifa 2011, Halle 

12, Stand A16. 

� 

tube rolling mills, cold and hot rolling mills 

as well as strip processing lines benefit from 

ABB’s state-of-the-art technology. ABB’s 

electro-magnetic stirrers deliver metallurgical 

competence for the primary industry, whereas 

ACS6000 drives offer reliable closed-loop 

control for single- and multi-motor drives in 

rolling mills of the metal conversion industry. 

As at the Metec eight years ago, ABB’s 

Industrial Cranes business unit will use the 

Düsseldorf trade fair platform to launch the 

new MoCon converter. 

Another focus of ABB’s trade fair activity 

will be the optimisation of melting plant engineering, 

i.e. maximising casting throughput 

through optimised casting sequences. Special 

attention will also be paid to the efficient use 

of electrical and thermal energy, a field ABB’s 

Energy Efficiency Consulting Service can display 

a long record of excellence. � 

Live at GIFA: 

20 tonnes compact 

frontlift with 

telescopic lift-arm for the 

handling of converters 

HUBTEX Maschinenbau GmbH & Co. KG · Werner-von-Siemens-Str. 8 · D-36041 Fulda · Tel.: +49-661-8382-0 · www.hubtex.com 

Genkinger-HUBTEX GmbH · Albstraße 49 · D-72525 Münsingen · Tel.: +49-7381-186-0 · www.genkinger-hubtex.com 

ABB


At the Gifa in Hall 17, the ABB division Discrete 

Automation and Motion presents its 

comprehensive performance spectrum along 

the entire value-added chain of the foundry 

industry. Furthermore, it shows numerous 

solutions and functional suites on efficiency 

and productivity in foundries far beyond the 

established robot portfolio. 

Besides its robots ABB will offer solutions, 

packages and integrated automation including 

safety, drive and control engineering. 

ABB will provide visitors with information 

on various new and advanced developments, 

such as special foundry robots and function 

packages with foundry-specific control cubicles. 

The so-called Foundry Controller includes 

robot control but can also safely host 

other drive and control units, such as the 

AC500 PLC – compact and safely equipped 

against sand, oil, metal dust and similar. 

Another highlight of ABB’s presentation 

will be the new vent hole piercer for sand 

castings. The great alternative to previous vent 

hole piercing systems is based on the IRB6620 

functional unit with integrated electrical 

piercing unit. Data received automatically 

from the moulding plant allows travelling to 

all points in the moulding box and accurately 

ASK Chemicals – leading producer of foundry aids 

ASK Chemicals Hilden is a leading manufacturers 

of foundry aids. The company offers 

the entire range of foundry chemicals and 

services across the whole value chain in a 

foundry – from core moulding to the melting 

process. Combined revenue in 2010 was 430 

million euros (USD550m). 

The profound understanding of foundry 

processes ranges from the design of castings 

via simulation services and the transfer of 

research results from the laboratory to production 

status, all the way to efficient series 

production of high-quality castings. The technology 

developed in laboratories and pilot 

systems provides customers with support in 

the constant optimisation of their processes. 

The products are manufactured regionally and 

close to the customer in production plants in 

Europe, the Americas and Asia. 

The product range comprises chemicals 

(binders, refractory coatings, sand specialities), 

feeding solutions and filters, services 

(simulation and core production) and metallurgy 

products (e. g. magnesium treatment, 

preconditioning and refining of melts). 

Among the latest developments and offers 

in the company’s product range is the ‘Inotec’ 

inorganic binder system, which has proved 

its suitability for mass production at BMW 

among others. Besides inorganic systems the 

further development of existing, highly efficient 

‘Cold-box’ binder systems is also impor- 

tant, since by using smaller amounts of binders 

these help to reduce emissions significantly. 

Altek Europe awarded Queens Award for Enterprise 

Altek Europe Ltd has been awarded the 

Queens Award for Enterprise – International 

Trade. Alan Peel, managing director of Altek 

Europe, commented: “This is a great moment 

for the company which we launched in 2007 

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to support the growth in aluminium produc- 

tion and recycling around the world. The 

company has a range of unique products that 

are recognised as world leading and are being 

used by hundreds of aluminium companies 

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piercing all required vent holes. 

But also where software is concerned, ABB 

has something to offer: the advanced Force 

Control (FC) Machining for robot-assisted deburring 

and grinding consists of a configured, 

ready-to-use functional unit for various, robot-based 

mechanical machining applications. 

Unlike conventional, robot-assisted deburring, 

grinding and polishing using time-consuming 

pre-programmed processing trajectories, CF 

Machining offers automatic adjustment of the 

robot arm to often uneven casting dimensions 

and thus significantly increased process efficiency. 

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Besides the reduction of harmful substances 

and further improving the quality of the castings, 

such product developments contribute 

toward higher productivity at manufacturers 

by cutting the costs of maintenance and dealing 

with emissions. 

With the recently founded ASK Chemicals 

TR Ltd in Ankara, the company is contributing 

toward Turkey’s industrial development. 

Turkey has become the largest foundry market 

in the Near East: approx. 1,200 foundries produced 

around one million tonnes of castings 

in 2009, and the annual growth rate is up to 

ten percent. 

ASK Chemicals is an exhibitor at Gifa, Hall 

12, Stand 24. 

� 

all over the world. The Altek team is small in 

its number of employees. However, the team 

here in the UK and our sub-contractors, as 

well as our strategic partners from all over 

the world have made this award possible. It 

is a great credit to the whole Altek team and 

their partners. We look forward to continuing 

our export growth and we are currently in the 

process of expanding our UK operations to 

support this initiative.” 

In addition to the range of aluminium dross 

cooling technology, Altek has also developed 

the ‘Siber Force’ electromagnetic stirring 

product range for circulating aluminium in 

melting furnaces; the tilt type rotary furnace 

(in conjunction with Mechatherm International), 

for aluminium recycling. During the first 


Indutherm 

SPECIAL 

three years of company trading, Altek Europe’s export earnings have 

increased 8-fold. The company clients include many of the largest 

aluminium companies in the world including the major international 

conglomerates such as Alcan, Alcoa, Hydro Aluminium, Rio Tinto 

and Rusal. Altek is an exhibitor at Gifa, Hall 9, Stand A49. � 

Indutherm Erwärmungsanlagen GmbH 

Lösungen für hochwertigen 

Feinguss in allen Metallen 

Indutherm aus Walzbachtal bei Karlsruhe zeigt auf der Gifa 

die ganze Bandbreite von Vakuum-Druckgießanlagen für 

Güsse von einem Gramm bis 30 Kilogramm (auf Aluminium 

bezogen). Darunter sind auch Lösungen für den Guss von 

Stahl, Platin, Palladium etc. Speziell diese Hochtemperatur- 

Gießanlagen sind mit einem Vibrationssystem für die Optimierung 

von Formfüllung und metallurgischen Eigenschaften 

ausgerüstet. 

Außerdem präsentiert das Unternehmen seine Vakuum-Stranggießanlagen 

für die Herstellung von Halbzeug wie Bänder, Drähte und 

Rohre. Durch das Schmelzen unter Vakuum wird das Metall „entgast“, 

Oxidationsprozesse beim Schmelzen werden weitestgehend 

Originalmodell, Wachsmodell und Gussteil aus Aluminium, gegossen mit 

einer Anlage der Indutherm VC-Serie 

unterbunden. Erstmalig wird die neue große Horizontal-Stranggießanlage 

VCC 12000 gezeigt, ebenfalls eine Vakuumanlage. Damit 

der Hauptvorteil der horizontalen Funktionsweise, die praktisch 

unbegrenzte Länge der produzierten Teile, auch ausgenutzt werden 

kann, verfügt die Anlage über ein Tiegelvolumen von 12.000 ccm. 

Indutherm verfügt nicht nur über hohe Anlagenbaukompetenz, 

sondern auch über umfassendes Prozess-Knowhow – sowohl aus der 

Beteiligung an zahlreichen Forschungsprojekten als auch aus der 

Entwicklung von Speziallösungen für Universitäten, Forschungsinstitute 

und Industrie. Auf Wunsch wird neben den Gießanlagen 

auch das komplette benötigte Equipment von der Einbett- bis Ausbettanlage 

aus einer Hand geliefert. 

Indutherm stellt in Halle 11, Stand C36 aus. 

� 


Entstaubungsanlagen 

für die Gießereiindustrie 

1 

2 

3 

Im Schmelzbereich für Konverter, Induktions-, 

Lichtbogen-, Kupol- und Drehtrommelöfen 

Für den Gießprozess und die Sandwirtschaft 

insbesondere mit Engineering und Fertigung von 

Erfassungselementen und Energiemanagement 

Für die Bereiche Brennen, Strahlen und Putzen mit 

Standardhauben und Absaugwänden bis zu kunden- 

und anwendungsspezifischen angepassten Arbeitskabinen 

Stichworte: 

· Kompetenz durch jahrzehntelange 

Betätigung in der Branche 

· Breites Produktspektrum lieferbar 

· Komplettlösungen aus einer Hand 

NEOTECHNIK und MÜNSTERMANN – 

Ein starkes Team für unsere Kunden und die Umwelt! 

Karten für die GIFA: 

info@mn-filtration.com 

GIFA 2011 

in Düsseldorf 

28.06.-02.07.2011 

Stand 17D15 

www.mn-filtration.com


25 years of Druckguss Service Deutschland GmbH 

For 25 years Druckguss Service Deutschland 

has been offering a comprehensive 

service for die casting machines. The company 

combines hydraulics, electronics and 

the mechanical manufacturing to a service 

package, which many customers appreciate 

worldwide. This also includes a well 

working network of cooperation partners 

which will be presented at Gifa 2011. 

On the European market the company is cooperating 

with the Taiwanese machine manufacturer 

Zitai. The two companies will jointly 

show a 900-tonne die casting machine at Gifa. 

Furthermore, there will be presented an R&D 

project which is related to the realisation of 

the interfaces of the die casting cell with a 

standardised, internet-based bus system. Thus, 

the communication between the administration 

and production is to be substantially simplified. 

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Klein Anlagenbau: Pneumatische Förderung und Kernsandaufbereitung 

Die Klein Anlagenbau AG präsentiert 

sich auf der Gifa (Halle 15, Stand J03) 

vor allem mit ihrer pneumatischen Fördertechnik 

und Kernsandaufbereitung. 

Speziell für den Transport von körnigem 

Schüttgut wie Gießereisand wurde der pneumatische 

Druckgefäßförderer Typ SP-HL entwickelt. 

Ausgestellt wird eine Tandemanlage, 

wobei zwei Druckgefäßförderer auf eine Förderrohrleitung 

arbeiten. Bei dieser Anordnung 

lassen sich Förderleistungen von mehr als 20 

Tonnen pro Stunde erzielen. Der SP-HL bietet 

laut Klein hohe Förderleistungen bei circa 

40 Prozent niedrigerem Energieverbrauch 

im Vergleich zu Förderern des Wettbewerbs. 

Darüber hinaus zeichnet er sich durch eine 

schonende Förderung, bei der die Struktur 

des Quarzkorns erhalten bleibt, sowie durch 

einen minimalen Verschleiß der Förderrohrleitungen 

und geringen Platzbedarf aus. 

Außerdem bietet das Unternehmen pneumatische 

Transportsysteme für alle anderen in 

der Gießerei anfallenden Stoffe wie Bentonit, 

Kohlen- und Filterstaub, die unterschiedlichsten 

Additive usw. 

Ein weiterer Messe-Schwerpunkt wird die 

Kernsandaufbereitung sein. Hier werden alle 

zur Kernsandaufbereitung notwendigen Aggregate 

wie Dosierwaage, Kernsandmischer 

Druckguss Service Deutschland is an exhibitor at Gifa, Hall 11, Stand D62 

Klein Anlagenbau 

„Statormix“, Bindemitteldosiereinheit 

und Kern- 

Geöffneter Kernsandmischer „Statormix“ 

sandverteilwagen ausgestellt. Der Statormix 

verfügt über ein energiesparendes Mischver- 

fahren sowie ein integriertes Selbstreinigungssystem. 

Für die im Mischraum eingesetzten 

Teile werden hochverschleißfeste Werkstoffe 

eingesetzt, mit denen besonders gute 

Standzeiten erzielt werden. 

Mit diesen Faktoren bietet 

der Kernsandmischer 

höchste Mischqualität, 

hohe Mischleistung bei 

geringem Bindemittelverbrauch 

und 

minimalem 

ReinigungsundWartungsaufwand.Besonders 

bei der 

A u f - 

bereitung 

von 

Kernsand 

mit anorganischen 

Bindemitteln zeigt der Kernsandmischer 

Statormix gute Ergebnisse. 

Im Vergleich zu anderen 

Kernsandmischern konnten die gleichen Festigkeitswerte 

mit bis zu 30 Prozent weniger 

Bindemitteleinsatz erzielt werden, betont das 

Unternehmen. 

� 


Druckguss Service Deutschland


StrikoMelter mit verbessertem Wirkungsgrad 

Die aktuellen Entwicklungen von StrikoWestofen 

für den Leichtmetallguss zeichnen sich 

durch günstigen Energieverbrauch sowie hohe 

Metallausbeute und -qualität aus. Grundlage 

dafür sind neben geeigneten Engineering- 

Werkzeugen, die zum Einsatz kommen, modernste 

Feuerfest- und Isoliermaterialien für 

die Gestaltung der Ofengeometrie. So wurde 

von den Wiehler Ingenieuren durch ganzheitliche 

Betrachtung von Ofenkörper, Feuerfestzustellung 

und Brennerdesign der Wirkungsgrad 

des bekannten StrikoMelter deutlich 

verbessert. Möglich wurde dies durch eine 

Ofenauslegung auf Basis einer Simulation des 

Wärmetransports mit CFD (Computational 

Fluid Dynamics) sowie mit FEM-Festigkeitsberechnungen 

für die Stahlkonstruktion. 

Nicht nur von außen hat der Aluminium- 

Schachtschmelzofen ein neues Erscheinungsbild. 

Bei unveränderter Bauhöhe sinkt der 

Energieverbrauch im gesamten Prozess gegenüber 

dem bekannten StrikoMelter mit ETAmax-Abwärmenutzung 

nochmals signifikant. 

Nachhaltigkeit und Ressourcenschonung zeigen 

sich jedoch erst dann, wenn der gesamte 

Lebenszyklus eines Ofens betrachtet wird. 

Deshalb wurde die Ofenzustellung komplett 

überarbeitet, mit entscheidenden Verbesserungen 

in Bereichen hoher mechanischer Beanspruchung 

und bei den verwendeten Isoliermaterialien. 

So können die Kunden nicht nur 

deutliche Einsparungen bei den Betriebskosten 

verbuchen, sondern auch längere Standzeiten 

und niedrigere Reparaturkosten. 

Als weitere Innovation wird ein modifizierter 

Dosierofen Westomat auf der Gifa 

(Halle 11, Stand C50) ausgestellt, der höchste 

Prozesssicherheit beim Guss dünnwandiger 

Strukturbauteile bietet. Mit deren zunehmender 

Verwendung im Bereich Chassis und 

Karosserie steigen auch die Anforderungen 

an Metalldosiersysteme hinsichtlich Dosiergenauigkeit, 

Gießtemperaturkonstanz und 

Metallqualität. Der Westomat mit verlängertem 

Steigrohr wird diesen Anforderungen 

umfassend gerecht. Das reine Metall wird 

Spouts and Stoppers Ceramic Foam Filters 

www.drache-gmbh.de · mail@drache-gmbh.de 

unterhalb der Badoberfläche entnommen 

und turbulenzarm in die Füllkammer der 

Druckgießmaschine dosiert. Der Kontakt mit 

oxidierender Atmosphäre ist minimiert; Metallreaktionen 

und oxidische Einschlüsse sind 

quasi ausgeschlossen, die Voraussetzungen 

für Gussteile der geforderten Festigkeit und 

Zähigkeit. Dafür verbraucht der geschlossene, 

elektrisch beheizte Dosierofen laut Unternehmen 

nur circa 30 Prozent der Energie im Vergleich 

zu Schöpföfen. 

� 

Grafik: 

StrikoWestofen 

For Aluminium DC Casting 

Numerische Strömungssimulation 

zur Ofenoptimierung 


KUNST IN ALUMINIUM 

Hyperrealistische Aluminiumplastiken 

Wenn das Wirkliche und Lebendige zur Kunst wird 

Bernd und Heike Rose Schmidt-Pfeil präsentieren ihre Arbeiten auf der Gifa 

Die Künstler Bernd und Heike Rose Schmidt-Pfeil wurden von der Messe Düsseldorf eingeladen, auf der 

Gifa, Metec, Thermprocess und Newcast 2011 eine Reihe ihrer Aluminiumskulpturen auszustellen, die sich 

durch eine hyperrealistische Ausdruckskraft auszeichnen. Schon auf der ALUMINIUM 2010 in Essen hatte 

das Künstler-Ehepaar zahlreiche seiner Arbeiten präsentiert und großen Zuspruch erfahren. 

Bernd und Heike Rose Schmidt-Pfeil sind Bildhauer, 

die mit ihrer Kunst die menschliche Existenz im 

technologischen Zeitalter reflektieren. Um ihren Aluminiumskulpturen 

einen hyperrealistischen Ausdruck 

zu verleihen, werden zum Beispiel Wachshohlfiguren 

unter Wärmeeinwirkung in Haltung, Gestik und 

Oberflächenstruktur künstlerisch gestaltet. Zahlreiche 

Arbeitsschritte sind erforderlich, bis aus einer solchen 

Wachshohlfigur am Ende die in Aluminium gegossene 

Skulptur entsteht. 

Die Künstler arbeiten dabei mittels Wachsausschmelzverfahren, 

bei dem eine Wachspositivfigur 

durch Einformen in einen Gipsschamottziegelmantel 

und abschließendes Ausschmelzen des Wachses 

eine Gießform geschaffen wird, die als Brennform 

für die metallische Positivform der gewünschten 

Figur verwendet wird. Kleidungsstücke, Schuhe, 

Hüte und andere Originalteile werden zuvor auf die 

Wachshohlfigur montiert und dort durch Tränken mit 

Wachs stabilisiert. Dieses Verfahren ermöglicht es, 

die Textilien der bekleideten Figuren hyperrealistisch, 

teils auch überzeichnet realistisch darzustellen. 

Für den Aluminiumguss wird eine Legierung 

mit sehr hohem Siliziumanteil verwendet, um die 

Viskosität des geschmolzenen Metalls so weit wie 

möglich herabzusetzen. Als Gießmetall wird insbesondere 

eine GALSi 12,5 Legierung verwendet. Die 

Legierung mit der Silizium-Beimengung von 12 bis 

12,5% weist bei einer Temperatur um die 690 °C 

fast die Viskosität von Wasser auf, wodurch selbst 

feinste Strukturen der Textiloberflächen, Haare und 

Frisuren hervortreten. Das AlSi-Gussverfahren ist eine 

eigenständige, patentierte Entwicklung des Künstlers 

Bernd Schmidt-Pfeil. Es ist, wie es der Kunsthistoriker 

Andreas Dunkel anlässlich einer früheren Ausstellung 

der beiden Künstler formulierte, „ein Verfahren, das 

ganz buchstäblich mit höchstem Energieaufwand 

auf das Wirkliche und Lebendige zugreift, um es zu 

Kunst werden zu lassen.“ 

Der teils sehr aufwendige, gestalterische Arbeitsprozesse 

ist einzigartig, „der eigentümlich matte, bei 

entsprechender Bearbeitung auch leuchtende Glanz 

macht die Oberflächenoptik des Aluminiums unverwechselbar“, 

so Dunkel. Die Arbeiten von Bernd 

und Heike Rose Schmidt-Pfeil seien „gewissermaßen 

Zeitmaschinen, welche die klassisch skulpturalen 

Techniken mit modernen, aus industriellen Produktionsprozessen 

abgeleiteten und erweiterten Verfahren 

miteinander kombinieren.“ 

Weitere Arbeiten des Künstler-Ehepaares wurden in 

ALUMINIUM 4/2011 veröffentlicht. Informationen 

und Kontaktdaten auch unter www.Schmidt-Pfeil. 

homepage.t-online.de 


ART IN ALUMINIUM 

Hyper-realistic aluminium sculptures 

When real life becomes an art form 

Bernd and Heike Rose Schmidt-Pfeil present their work at Gifa 

The artists Bernd and Heike Rose Schmidt-Pfeil were invited by Messe Düsseldorf to exhibit at Gifa, Metec, 

Thermprocess and Newcast 2011 a range of their aluminium sculptures, which are noted for their hyperrealistic 

expressive force. Already at ALUMINIUM 2010 in Essen the artist husband-and-wife team has presented 

many of their works, to great acclaim. 

Bernd and Heike Rose Schmidt-Pfeil are sculptors 

whose art reflects the human condition in the technological 

age. To give their aluminium sculptures a 

hyper-realistic impression, for example hollow wax 

figures are artistically modified by the action of heat 

to display various attitudes, gestures and surface 

textures. Many working steps are then required to 

arrive, starting from such a hollow wax image, at the 

final, cast aluminium sculpture. 

The artists work with the lost-wax process in 

which a wax positive is made into a casting mould 

by first covering it in a plaster fireclay coating and 

then melting out the wax, and finally using the 

resultant mould to produce the positive shape of the 

figure desired in cast metal. Garments, shoes, hats 

and other original features are fitted beforehand 

onto the hollow wax figure and stabilised in position 

by soaking with wax. This method enables the textiles 

of the clothed figures to be represented hyperrealistically, 

even to an exaggerated extent. 

For the aluminium casting an alloy with very 

high silicon content is used, in order to reduce the 

viscosity of the molten metal as much as possible. 

As the casting metal GAlSi12.5 in particular is used. 

At a temperature of around 690°C the alloy with 

silicon content 12 to 12.5% has almost the same 

viscosity as water, so it can conform even to the finest 

structures of textiles surfaces, hair and hairstyles. 

The AlSi casting process is an independent, patented 

development by the artist Bernd Schmidt-Pfeil. As 

the art historian Andreas Dunkel put it on the occasion 

of an earlier exhibition by the two artists, it 

is “a method which quite literally, with a great deal 

of effort and energy, grasps the real and lifelike to 

make art of them”. 

The sometimes very elaborate creative working 

process is unique. “The inherent matt, but when appropriately 

processed also brightly shining surface, 

makes the visual effect of the aluminium inimitable,” 

says Dunkel. The works of Bernd and Heike Rose 

Schmidt-Pfeil are “as it were, time machines which 

combine classical sculptural techniques and extend 

them with methods derived from industrial production 

processes”. 

Further works by the artists were published in 

ALUMINIUM 4/2010. Information and contact data 

can be obtained at www.Schmidt-Pfeil.homepage. 

t-online.de 



Thermprocess 2011 

Increasing innovation potential by virtue of energy efficiency 

Energy saving and energy efficiency are terms 

known from the private, or domestic field and 

are mentioned in the sales-talk as a decision 

criterion in connection with any purchase of 

refrigeration units or heating installations. But 

in the industrial sector as well, these terms are 

current in the context of mechanical engineering 

and in particular thermal process technology, 

and the corresponding supplier industries. 

Thermal processing units (or more commonly: 

industrial furnaces), due to the manner 

of their operation, are major consumers of 

energy. For furnace manufacturers energy efficiency 

is not at all a new subject. If the energy 

consumed by units built in the past decades (or 

even earlier) is compared with what is nowadays 

typical, it is quite evident that energy 

losses are becoming continually lower. 

The potential for energy saving varies depending 

on the age of a thermal processing 

unit. Many modern units demand a third less 

energy that old plants. Yet, even with new 

equipment possible reductions of consumption 

are estimated as up to 15 percent if the plant 

design is optimised, the plant integrated thermally 

into the production process as a whole, 

or the waste heat used. 

Thermal processing technology is a key factor 

that plays a major part in numerous production 

processes: on the one hand for producing 

Hertwich Engineering 

Hertwich Engineering – market leader 

with continuous homogenising plants 

Hertwich Engineering, a company of the SMS 

group, is active worldwide with design, supply, 

construction and commissioning of speciality 

machinery and equipment for the aluminium 

industry, in particular for aluminium casthouses. 

The product range comprises the following 

technically advanced machinery and equipment: 

the starting material for the production chain 

and on the other hand for the controlled tempering 

of semis or finished products. Innovation 

and efficiency together with the rational 

treatment of energy and compliance with strict 

environmental tolerance demands are characteristic 

of the branch. As suppliers of equipment 

and services, manufacturers achieve 

optimum solutions by virtue of close collaboration 

and involvement with their customers. 

In the fields of iron and steel, NF-metals, 

glass and ceramic production and for the entire 

range of further processing during the production, 

shaping and quality adjustment of material 

and component properties by appropriate 

heat treatment and surface finishing, thermal 

processes are of fundamental importance and 

are, moreover, also used for optimising product 

properties. Process-technical consultancy 

and engineering for plant planning are core 

competences which are present in abundance 

among the manufacturers of thermal processing 

equipment. Thermal processing equipment 

is predominantly operated by manufacturers 

together with the upstream and downstream 

plant parts and systems as integrated solutions. 

As a key element in almost every segment 

of industry, thermal process technology is decisively 

important for the technical competi- 

• Continuous and batch homogenising plants 

• Sawing plants 

• Horizontal DC casting machines 

• Ultrasonic inspection stations 

• Melting equipment for aluminium scrap etc. 

With continuous homogenising plants for extrusion 

billet (see photo) Hertwich maintains its 

worldwide lead since many years 

(90% market share). With advanced 

melting technology Hertwich has in 

recent years revolutionised the industry. 

The company is competent for 

supplying complete aluminium casthouses 

on a turnkey basis (one-stopshopping). 

To stay ahead Hertwich 

relies on its own R&D and proprietary 

know-how. 

Hertwich is an exhibitor at Metec 

2011, Hall 5, Booth F16. 

tiveness of branches such as the automobile, 

aerospace, mechanical engineering, metallurgical 

and foundry industries. 

Technology trends 

The careful use of energy and resources is the 

technology trend of recent and future years, 

which also leads to technological developments 

in other fields. Below, a number of important 

technology trends are described. 

• Holistic energy consideration of production 

sites and thermal processing units: the input 

resource flows (energy, water, other materials) 

of plants and plant components have to be 

coupled and matched with one another. 

• New burner types with lower emissions and 

higher efficiency: in heat production, the use 

of so-termed regenerators, recuperators or 

heat exchangers, whether external or built into 

the burners, can generate very high air preheat 

temperatures and thus high flame-technological 

efficiencies. The associated negative influences 

on the emission of harmful substances 

have been dealt with: emissions have now 

fallen below the statutory limit values for nitrogen 

oxide (NO x) and CO. 

• Integration of energetically optimised individual 

components: the energy consumption 

of fans, pumps and electric motors has been 

reduced in recent years, among other things 

also because of European and international 

standard specifications. Such components are 

used in an optimised manner at every stage of 

thermal processing plants. 

• Using the energy present in exhaust gases 

and sometimes even coolants: in recent years, 

although known methods for energy reduction 

have become technically feasible, they have 

not been economically viable. But, not least, 

increasing energy prices are bringing about a 

change in this respect. 

• Robots and handling systems: new handling 

systems and flexible storage systems with 

new loading pallets are coupled with thermal 

processing units to create flexible and very 

flexible production plants. 

• New safety concepts motivated by new statutory 

requirements: in Europe control systems 

and entire machines are undergoing reassessment 

because of new statutory specifications, 

and are therefore becoming even safer. 

The design and production of thermal 

processing plant is nowadays the result of a 

long chain. The operator first specifies or describes 

the process and the plant manufacturer 


Eisenmann 

SPECIAL 

then indicates possible solutions. Computer-supported simulations 

are carried out, which also take into account the properties of the 

materials. The product is then tested at a technical centre. A final 

step is the integration and linking of the new plant with existing 

production facilities. 

However, these new techniques and methods are not just applied 

in new plants. Manufacturers of thermal processing equipment 

have also specialised in modernising old plants and making 

them more economical with the aid of new modules. 

The companies concerned are mainly medium-sized, which enables 

great flexibility and dynamic adaptation to change. Associated 

with this is consistent market orientation. 

Thermprocess Symposium 

At this year’s trade fair too, a Thermprocess Symposium will be 

held. It will take place in the Thermprocess Exhibition Hall so 

that visitors to the fair can also participate in the symposium. The 

symposium will take place from 29 June to 1 July, between 10 

am and 4 pm each day. Attendance at the symposium is free for 

GMTN visitors. 

A number of main themes have been selected for the symposium: 

• Energy efficiency of thermal processing equipment 

• Life-cycle costs 

• New safety concepts 

• Special processes, components and applications 

• Heating and burner technology 

• Cooling, quenching, recovery of heat. 

Visitors can find out about the technical innovations of the companies 

presenting lectures and exhibits. 

� 

E-Gate – the new high-temperature 

vacuum door from Eisenmann 

The new high-temperature vacuum door E-Gate from Eisenmann 

The internationally operating plant engineering company Eisenmann 

will present its portfolio of high-temperature technology in 

Hall 10, Stand G58, at Thermprocess 2011. Attention will focus 



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on the new high-temperature vacuum door 

E-Gate. The double door system is designed 

for temperatures up to 1,700°C. For the first 

time, it allows rapid changes of atmosphere 

within a high-temperature zone. In this way, 

high throughputs can be handled even when 

zones with different atmospheres and pressure 

conditions have to be separated at high 

temperatures. 

Until now, complex thermal processes with 

high atmosphere requirements were operated 

Sapa RC Profiles is the largest producer of 

aluminium profiles in Belgium, with locations 

in Lichtervelde and Ghlin 

and an annual production 

of 45.000 tonnes. 

The foundry department 

at Sapa in Ghlin produces 

aluminium logs and billets 

for the extrusion process. 

This foundry will nearly 

double its production capacity 

this summer by the 

installation of a new melting 

furnace which is designed 

and realised by De 

ecoMetals-Kampagne zeigt 

Innovationskraft der Unternehmen 

Das Streben nach Energieeffizienz und der sparsame Umgang mit natürlichen 

Ressourcen entwickeln sich in der gesamten Wirtschaft zu einem 

Megatrend. Das Messequartett Gifa, Metec, Thermprocess und Newcast 

(GMTN) präsentiert besonders nachhaltige Neuheiten innerhalb der neuen 

Kampagne „ecoMetals“. 

Aussteller, die substanzielle Neuheiten im Bereich Energie- und Ressourceneffizienz 

präsentieren, stehen durch die Teilnahme an der „ecoMetals“-Initiative 

besonders im Fokus. Auf der Messe werden Exponate und Stände 

teilnehmender Unternehmen mit dem ecoMetals-Logo markiert. Nicht nur 

effizientere Maschinen und Anlagen sind gefragt – der ecoMetals-Ansatz 

umfasst auch fortschrittliche Verfahren, Dienstleistungen und Lösungen, die 

am Ende dem Klima und der Wirtschaft gleichermaßen nützen. „Als Veranstalter 

der internationalen Leitmesse greifen wir ein solch bedeutsames Thema 

natürlich auf“, so Friedrich-Georg Kehrer, Director des Messe-Quartetts. 

„Alle präsentierten ecoMetals-Lösungen haben den Anspruch, bahnbrechend 

für den jeweiligen Markt, zukunftsfähig und nachhaltig wirksam zu sein.“ 

Mehr als zwei Dutzend Firmen der Gießereibranche, des Industrieofenbaus 

und von Wärmebehandlungsanlagen beteiligen sich an der ecoMetals- 

Kampagne, unter anderem die Unternehmen Ebner, Magma, LOI Thermprocess 

und Schwartz. 

discontinuously using vacuum batch kilns in 

order to realise rapid changes of atmosphere. 

The new high-temperature vacuum door E- 

Gate, on the other hand, permits continuous 

operation with atmospheres separated at high 

temperature and can be incorporated into production 

lines optimised for high throughput 

and cost effective production. Designed as a 

double door system, it is installed in high-temperature 

roller-type kilns from Eisenmann. 

Eisenmann is one of the leading interna- 

De Winter Engineering supplies melting furnace to Sapa Ghlin 

Winter Engineering (Netherlands). De Winter 

will replace the existing stationary melting 

furnace by a new, tiltable 

version equipped with an 

electromagnetic stirrer 

from Altek. The existing 

burner installation will be 

renovated and increased. 

The new melting furnace 

will be built next to the 

existing furnace. The 

Photo: De Winter 

company Engineering will 

also renovate the existing 

holding furnace and increase 

its bath content. 

tional suppliers of general finishing technology, 

materials flow automation and environmental 

technology as well as high temperature 

technology. Close to 2,800 qualified employees 

develop new technologies and facilities for 

production, assembly and distribution. Engineers, 

technicians and specialists from various 

disciplines handle the planning, design, construction 

and start-up operation of the most 

advanced systems, including maintenance and 

system operation. 

� 

The liquid metal produced by the new melting 

furnace will be exclusively won from scrap. 

Different sorts of scrap will be melted which 

will mainly originate from other Sapa units. 

This recycled metal will be turned into high 

quality logs and billets. 

Since 1985 De Winter Engineering has 

been constructing and renovating melting and 

holding furnaces and related equipment for 

the non-ferrous metals industries. This experience 

and the technical know-how in furnace 

technology form the basis of its high quality 

designs. 

De Winter Engineering is an exhibitor at 

Thermprocess, Hall 10, Stand F70. � 

ecoMetals campaign shows 

companies’ innovation prowess 

The pursuit of energy efficiency and the economical use of natural resources 

are establishing themselves as megatrends in all areas of the 

economy. The Gifa, Metec, Thermprocess and Newcast (GMTN) trade fair 

quartet will be presenting especially sustainable innovations within the 

new ‘ecoMetals’ campaign. 

With the ecoMetals campaign, the organiser Messe Düsseldorf will be 

spotlighting outstanding innovations of GMTN exhibitors. At the trade 

fair, exhibits and stands of participating companies will be marked with 

the ecoMetals logo. More efficient machines and systems are not the 

only things needed – the ecoMetals approach also includes progressive 

processes, services and solutions, all of which ultimately benefit both the 

climate and the economy. “As organisers of the trade fair, it is only natural 

for us to focus on such an important theme,” Friedrich-Georg Kehrer, director 

of the trade fair quartet says. “All of the ecoMetals solutions being 

presented can claim to be groundbreaking in their respective markets, 

viable and sustainable.” 

Over two dozen companies – from foundries to industrial furnaces 

(recycling plants and heat treatment facilities) – will be participating in 

the ecoMetals campaign, including Ebner, Magma, LOI Thermprocess and 

Schwartz. 


LOI Thermprocess 


LOI recycling technology with outstanding low energy consumption 

LOI Thermprocess is among the leading suppliers 

of industrial furnaces for the aluminium 

industry. The process expertise available in- 

The TCF twin-chamber melting furnace from LOI Thermprocess 

cludes secondary melting and recycling furnaces 

as well as heat treatment furnaces for 

semi-finished and finished products. 

For the 

melting of contaminated,thinwalled 

scrap 

LOI delivers the 

Twin-Chamber 

Melting Furnace 

(TCF) with 

integrated afterburn. 

In connection 

with a flue 

gas purification 

plant, a highly 

efficient plant 

for the recycling 

of aluminium 

scrap is available: 

without 

salt, with low 

energy con- 

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sumption, with a high metal yield and forced 

circulation of the melt. 

The new recycling furnace sets standards 

with its energy figures. The specific energy 

consumption guaranteed by LOI is given as 

670 kWh of natural gas energy per tonne of 

aluminium melted, and in addition 50 kWh of 

electric power (including the operation of the 

flue gas treatment plant), and the operating 

figures are even lower than these values. This 

is also related to the fact that adhering organics 

(the lacquers) are used directly to produce 

energy and do not have to be burned away in 

an afterburner with additional energy input. 

Aluminium Norf, the largest aluminium 

rolling and remelt plant in Europe, has been 

operating a TCF furnace since 2009 and obviously 

with good result. Only recently the company 

has awarded LOI the order of a second 

TCF-type recycling furnace. 

LOI is an exhibitor at Thermprocess, 

Hall 9, Stand C62. 

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Ebner 


New artificial ageing line for volume production of aluminium engine blocks 

A turnkey artificial ageing line for a largescale 

manufacturing application was realised 

by BSN Thermprozesstechnik GmbH, located 

in Simmerath, Germany, within a minimum 

turnaround time despite major installation 

space constraints. 

The furnace system is of modular design 

and features a 2-storey roller hearth measuring 

more than four metres in width. The products 

Due to the continued high demand for aluminum 

foil, expansion phase 2 of Constantia 

Teich’s rolling mill II was started sooner than 

originally planned. The expansion will double 

the throughput of rolling mill II. The necessary 

equipment was delivered by the same 

suppliers and contractors as in 2007, including 

Ebner as the supplier of the required heat 

to be heat-treated are conveyed in a highly 

flexible manner on cast-iron trays loaded by 

robots. The directly natural gas fired system 

delivers a throughput of 7,500 kg/h. 

The trays carrying the cooled-down product 

return above the furnace through an air-cooled 

zone with an optimised regenerative cooling 

air preheater (for operation in winter). 

In order to prevent excessive product dwell 

treatment furnace facilities. 

The existing heat treatment facility 

for foil semi-finished products 

was expanded by two gas-fired radiant 

tube heated single-chamber 

batch-type furnaces. Both new 

furnace chambers, like the single-chamber 

batch-type furnaces 

of construction phase 1, are integrated 

into the customer’s production 

process planning system and 

operate fully automatically. Like 

in the existing facility, extremely 

short heating-up times are achieved 

thanks to Ebner’s high-convection 

technology, combined with a perfectly suited 

nozzle system. 

Moreover, parameters for the annealing 

process are calculated offline in advance, using 

the Batch-type furnace Optimisation System 

(BOS) developed by Ebner. The real-time 

checks and automatic correction if required 

during the annealing process guarantee the 

times in the furnace in the case of a standstill 

in downstream line processes, the system is 

equipped with buffer sections. These product 

buffer sections are likewise arranged above 

the furnace and have a capacity equivalent to 

one complete furnace load. The entry and exit 

of trays into and from the buffers is centrally 

visualised via the furnace control system and 

is managed automatically using a bar code 

scanner system. 

Further to the technical features described 

above, the special installation situation merits 

special mention. For space reasons, the individual 

equipment units – including the elevators 

– were fitted on top of one another in 

an arrangement extending up to 14 metres in 

height. For walk-on access and maintenance, 

the installation is equipped with a structure 

of platforms and stairs. Moreover, the entire 

furnace system (having a total weight of more 

than 300 tonnes) is supported on 12 pillars 

at a height of approx. 4 m above floor level. 

Owing to this configuration, production floor 

traffic was able to pass under the furnace 

throughout the installation phase and can 

continue doing so in the future. 

BSN is an exhibitor at Thermprocess 2011, 

Hall 9, Stand B34. 

� 

Ebner heat treatment furnaces for rolling mill II expansion at Constantia Teich 

Dual-chamber batch-type furnace facility with a total of 12 

chambers. Net charge up to 35 tonnes foil coils per chamber. 

shortest production times, while ensuring that 

all necessary annealing parameters are being 

observed without using any charge thermocouples. 

At the same time the BOS supports 

the production control system in scheduling 

the best material flow. 

The finished foil annealing facility has 

been expanded by three gas-fired radiant tube 

heated dual-chamber batch-type furnace facilities, 

installed in a way which allows the 

existing charging machine to be used. As with 

the 2007 facility, the two chambers of each 

furnace facility can be independently operated 

and have no influence on each other. The existing 

charging machine can be used for each 

individual furnace chamber of the three new 

dual-chamber batch-type furnace facilities, 

which enables a seamless integration into the 

automatic operation process of the existing 

facility. Both types of facilities started up successfully 

at the end of November 2010. 

Ebner is an exhibitor at Thermprocess 

2011, Hall 9, Stand A38. 

� 


BSN Thermprozesstechnik

Images: Otto Junker 


Otto Junker presents an innovative gas-fired 

billet heater for high-efficiency aluminium billet heating 

At Thermprocess 2011, Otto Junker will 

be presenting a billet heater which manages 

to retain the flexibility of the direct 

flame impingement while providing the 

efficiency of a convection heated unit. 

With the potential inclusion of the German 

aluminium processing industry in an expanded 

emissions trading scheme looming as of 2013, 

the objective of saving energy has become more 

important than ever. This also and quite par- 

ticularly applies to the furnace equipment employed 

in extrusion plants for heating aluminium 

logs or billets to the hot forming temperature. 

Gas-fired heating processes merit special 

consideration in this context. Given the 

Fig. 1: Convection furnace of Otto Junker design (left) and measured heat-up curve (right) reflecting a temperature accuracy of better than +/- 5K with billets 

measuring 550 mm in diameter and 1,800 mm in length. The energy demand throughout the reference measurement was lower than 180 kWh th /t Al at a throughput 

of 7,310 kg Al /h and a draw temperature of 500°C. 



Fig. 2: Schematic drawing of the combination-type gas-fired billet heater (‘KombiGAS’) 

natural gas / electricity price ratio prevailing 

in Germany and the specific CO 2 emissions 

produced with the current German mix of 

electricity sources, efficiency gains in gas- 

fired heating processes will improve both the 

overall economic CO 2 balance and the corporate 

cost burden. 

Billet heaters with direct flame impingement, 

as established in the market for several 

decades, have been continuously refined by 

all renowned suppliers. Still, it is to be assumed 

that their energy efficiency has its design-inherent 

limits. As an alternative to this 

technology, Otto Junker installed a convection 

heater at the Alcan plant in Singen as far 

back as in the late 1990s. This heating system, 

an innovative solution at the time, provided 

significant efficiency gains over conventional 

billet heaters. On the other hand, it imposed a 

compromise on flexibility which is why induction-type 

single-billet heaters were installed 

downstream of the convection heater. 

On the occasion of the Thermprocess trade 

fair, Otto Junker now presents a combination 

(patent pending) of the two above-mentioned 

equipment types which manages to retain the 

flexibility of the direct flame impingement 

while providing the efficiency of a convection 

heated unit. 

State of the art in 

gas-fired billet heating 

Heaters with direct flame impingement: Gasfired 

heaters based on a direct application 

of the flame to the metal are usually made 

up of two main assemblies. At the exit end, 

the aluminium billets are heated in a directly 

gas-fired section by a multitude of burners of 

relatively low output (8 to 12 kW) installed in 

a refractory-lined muffle adapted to the billet 

geometry. 

Of the total heat input reaching the aluminium 

billet, convective heating by direct 

flame impingement accounts for around 30% 

whereas radiation heating contributes around 

70%. Given the reduced emission factor of 

machined billets, throughput is likely to be 

lower with this billet type (due to the high radiation 

portion) than with unscalped aluminium 

still carrying the casting skin. The temperature 

control quality of a gas-fired billet heater depends 

on the number of its control zones. 

Upstream of the direct heating section, a 

so-called preheating chamber is normally arranged 

at the entry end. In this preheating 

chamber, the billets are heated by forced convection 

using the exhaust gas from the gasfired 

section before it enters the exhaust stack. 

Thanks to the high transferable power density 

which may attain up to 150 kW per square 

metre of billet surface in the section of direct 

flame exposure, key benefits of this equipment 

type include its fairly small footprint and the 

capability to respond quickly to changing 

cycle times with the final billet temperature 

kept constant. The temperature loss in the billet 

head that results from clamping in the hot 

shear can likewise be recovered quickly. 

On the downside, the high power density 

achieved is owed to temperature differentials 

(flame-to-billet, muffle-to-billet) which harbour 

a risk of causing superficial fusion of the 

billet. Moreover, to minimise losses while ensuring 

acceptable wall temperatures, the high 

power densities produced call for an elaborate 

thermal insulation of the wall. This in turn 

raises the level of thermal inertia, so that the 

heater will be of limited flexibility, e. g. when 

it comes to making quick downward temperature 

adjustments. 

One widespread equipment technology 

involves the use of combustion air preheating 

and billet preheating chambers in which 

the exhaust air is recirculated by centrifugal 

fans. With a system of this type, efficiencies 

of 60 to 70% can typically be attained, 

even in part-load operation. Efficiency gains 

are achievable by preheating more intensely, 

e. g. by increasing the length of the preheating 

chamber or by using the magazine table for 

log preheating. On the other hand, the costs 

(investment, space requirements) and benefits 

(energy savings) must be compared by careful 

pre-investment analysis. 

Convection-type billet heaters: Like their 

gas-fired counterparts with direct flame exposure, 

these heaters are designed as multi-billet 

units. They are characterised in that heat 

is imparted to the billet almost exclusively by 

forced convection, i. e. hot gas is directed at 

high velocity onto the billet surface via spe- 

cially adapted tubular or slot-type nozzles. 

The hot gas is maintained at the required temperature 

in heating ducts extending separately 

from the billet, and it is recirculated by fans. 

The aluminium billet is not directly exposed 

to a flame. 

Heating is effected by recuperative burners 

delivering between 100 and 400 kW each. The 

achievable efficiency varies between 75 and 

85%. Due to the predominantly convective 

heat transfer, the throughput reduction associated 

with scalped billets is less pronounced 

than with a directly gas-fired billet heater. On 

the other hand, the power density transferable 

with this equipment type remains clearly below 

100 kW per sq.m. of billet surface area, 

meaning that the unit needs more floor space 

than a directly gas-fired billet heater. The temperature 

control quality likewise depends on 

the number of control zones with this kind of 

system; however, it is ensured first and foremost 

by setting the temperature of the last control 

zone to the final billet temperature (Fig. 

1). The risk of superficial fusion of the metal 

is thus virtually eliminated, and a particularly 

high temperature accuracy can be achieved. 

For design-inherent reasons, the system will 

obviously not support fast temperature changes, 

but the mathematical model included in 

the controller keeps the target temperatures 

of each control zone continuously adapted to 

the throughput rate. As the level of fuel efficiency 

will improve with decreasing process 

temperatures, thermal energy demand will 

drop in part-load operation. 

Combined gas-fired billet heating 

Otto Junker has now combined the above two 

state-of-the-art heater types in a special manner. 

A convection heater with recuperative 

burners is used to preheat the aluminium logs 

or billets to just below the extrusion temperature. 

The convection heater is immediately 

followed by an ‘in-line’ directly flame-heated 

section that has been kept as short as possible, 

having about 1 to 2 times the length of 

the billet. This latter section serves to achieve 

rapid temperature changes or to perform selective 

heating of the billet head. Moreover, 

this section compensates for the temperature 

drop resulting from clamping in the hot shear 

(Fig. 2). 

In order to boost the system’s efficiency, 

the exhaust gas from the directly flame-heated 

section is returned, preferably, into the first 

heating zone of the convection heater. On its 

way to the convection heater the exhaust gas 

may optionally be used for preheating the 

combustion air to the directly flame-heated 



Fig. 3: Comparison of thermal energy demand between a heater with direct flame 

exposure (‘conventional direct flame’) and the combination-type gas-fired billet 

heater (‘KombiGAS’), plotted for a system heating 10’’ aluminium billets to 480°C and 

achieving a throughput of 4,000 kg/h (100%) under optimum design conditions 

section. In part-load operation at under 75% of nominal throughput, 

the directly flame-heated section serves merely to compensate for the 

heat loss caused by withdrawing the logs for shearing or sawing. At 

the same time, the temperature of the convection heater is steadily 

reduced, which improves its fuel efficiency and reduces its thermal 

energy demand by around 10% from the nominal requirement in 

the most widely used part-load range (i. e. at between 30 and 50% 

load) (Fig. 3). 

Conclusion 

In summary, it can be stated that the combination of the two principles 

avoids the drawbacks of each while preserving the advantages 

of both. In particular, its efficiency under part-load conditions will be 

a major decision-making factor in future replacement or new investment 

projects: 

• particularly high efficiency at virtually all relevant load levels 

• reduced footprint compared to an all-convection heater 

• ability to accommodate rapid temperature changes 

• no negative effects of changes in billet surface state (as cast / scalped) 

• low risk of superficial billet fusion 

• low thermal load on the interior heater chamber, low wear 

• easy access, making the system more maintenance-friendly 

than a heater using direct flame impingement 

• supports any kind of conveyor system (walking beam, live 

rollers, idle rollers) 

• optional combination with hot shears or hot saw. 

The system thus rounds off the Junker’s product range by adding 

another building block holding significant future potential. This latest-generation 

combination-type heater can also be used along with 

a proven single-billet induction heater of Otto Junker design. In this 

case, the IGBT frequency converter technology developed in the 

company’s own R&D department and established since 2004 allows 

temperature gradients in any direction to be established with high 

accuracy and reproduced with perfect temperature precision. For 

each system from the range, tailor-made handling solutions designed 

to provide maximum space and time savings are available, covering 

the entire workflow from the magazine to the supply of hot billets to 

the extrusion press. Of course, each system comes with state-of-theart 

automation, with software engineering and commissioning being 

commonly carried out by Junker’s own specialists in close cooperation 

with the customer. 

Otto Junker is an exhibitor at Thermprocess 2011, Hall 10, Stand 

E20. 

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Ecomax 4C rounds off Elster Kromschröder’s 

series of self recuperative burners 

Elster Kromschröder is filling a gap in the 

series of ‘Ecomax’ ceramic self recuperative 

burners. The new 4C type has a burner capacity 

of 180 kW. To date, the ceramic version 

of Ecomax was available with a capacity 

range of up to 100 kW or as 5C type with a 

capacity of 250 kW. With its SiSiC recuperator, 

the 4C type is suitable for directly heated 

heat treatment processes in which metallic self 

recuperative burners either cannot be used or 

can only be used on a restricted basis. Since 

the self recuperative burner utilises the heat 

of the furnace flue gases to preheat the combustion 

air, as do all members of the Ecomax 

series, it significantly lowers the gas consumption: 

energy savings of up to 30 percent can be 

made, depending on burner model and mode 

of operation. The systems’ efficiency is thus 

increased considerably. 

All Ecomax burners have an integrated heat 

exchanger using the exhaust heat to preheat 

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the combustion air to a maximum of 700°C. 

Fields of application for the self recuperative 

burners are indirect heating 

systems with radiant tubes or direct 

heating systems in conjunction with 

an eductor for reabsorbing the 

flue gases by suction. The 

Ecomax series 

Recuperator burner Ecomax 

consists of a total of seven sizes and covers 

a capacity range from 25 to 500 kW. The self 

recuperative burners are available in metallic, 

all-ceramic or flat tube versions (M, C or 

FTR). Thus, Ecomax C has a ceramic recuperator 

made of SiSiC for a maximum 

application temperature up to 1,300°C. 

The cast steel ribbed tube recuperator 

of the Ecomax M ensures 

a maximum efficiency up to 

1150°C. All Ecomax burners 

feature direct electrical 

ignition and, depending on 

the application, are directly 

ionisation-controlled or 

monitored by a UV sensor. 

The extremely high flame outlet 

velocity and on/off control 

ensure precise temperature control 

and accuracy in the furnace. 

The Ecomax self recuperative burners will be 

presented at Thermprocess 2011 in Hall 9, 

Stand D22. 

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Metec 2011 in Düsseldorf 

Hütten- und Walzwerke – 

Vorsprung durch innovative Anlagentechnik 

Die große Bedeutung der Metalle, insbesondere 

von Stahl und Aluminium, wird 

durch die breite Anwendungspalette in 

sämtlichen Bereichen von Industrie und 

Wirtschaft sichtbar. Dazu tragen gerade 

die Verarbeitungstechnologien für diese 

Werkstoffe bei. Die Hersteller von Hütten- 

und Walzwerken liefern das komplette 

Anlagenequipment einschließlich 

Elektrik und Automation, das Verfahrens- 

Knowhow und sämtliche Services. Der 

Anlagenbauer bietet sowohl Gesamtanlagen 

als auch maßgeschneiderte Anlagenerweiterungen 

und Modernisierungen an. 

Diese Anlagentechnik macht es möglich, 

Halbzeuge wie 

Bleche, Rohre, Stäbe, 

Profile, Drähte 

und Schmiedestücke 

herzustellen, die 

die Grundlage für 

Produkte bilden, die 

der Endverbraucher 

nachfragt. 

Ausgelöst durch globale 

Umwelt- und Energiethemen 

wie Erderwärmung, 

CO 2 -Reduktion, 

Abfallvermeidung, 

ressourceneffizienter 

Materialeinsatz und Energieeinsparung 

müssen 

adäquate Technologien 

entwickelt werden, die 

diese Ziele erfüllen. Für 

den Anlagenbauer ist 

hierbei ganzheitliches 

Denken gefragt, dass 

fundierte Kenntnisse in 

Mechanik/Mechatronik, 

Automation und 

Technologie sowie ein 

tiefes Verständnis der 

Prozesskette verlangt, 

um innovative Anlagentechnik 

zu entwickeln. Dies setzt den Anlagenbetreiber 

in die Lage, flexibel auf Schwankungen 

der Rohstoffversorgung, eine geänderte 

Marktnachfrage und strengere Auflagen 

zu reagieren. 

Auch die Steigerung der Wettbewerbsfähigkeit 

der Kunden steht im Fokus der An- 

Metec 2011 in Düsseldorf 

Smelting and rolling plants – advances 

due to innovative plant technology 

The great importance of metals, especially 

steel and aluminium, is evident from 

the very wide range of their applications 

in every branch of industry and the economy. 

Processing technologies for these 

materials in particular contribute much 

toward this. The manufacturers of smelting 

and rolling plants supply the complex 

plant components including electric 

and automation equipment, the process 

know-how and all the required services. 

Plant engineers provide both complete 

plants and tailor-made plant extensions 

and modernisations. Such plant technology 

makes it possible to produce semis 

such as sheets, tubes, bars, sections, wires 

and forged components, which form the 

basis for the products demanded by end 

users. 

Motivated by global environmental and energy 

issues such as global warming, CO 2 reduction, 

avoidance of wastes, more resourceefficient 

use of materials and energy saving, 

it has become necessary to develop adequate 

Market share of major supplier countries of 

smelting and rolling mill equipment in 2009 

technologies that fulfil those aims. For this, 

plant manufacturers have to think holistically, 

with well-founded knowledge of mechanics 

and mechanical-electronics, automation and 

technology as well as a fundamental understanding 

of the process chain and the development 

of innovative plant engineering. This 


SPECIAL 

enables plant operators to react flexibly to raw strengungen des metallurgischen Maschinenmaterial 

supply fluctuations, varying market und Anlagenbauers, die durch Maximierung 

demand and stricter statutory and technical von Produktivität, Verfügbarkeit, Sicherheit 

requirements. 

und Umweltverträglichkeit über den gesam- 

Increasing the competitiveness of their ten Lebenszyklus der Anlage erreicht wird. 

customers is also at the focus of efforts by Immer leistungsfähigere Computer und 

metallurgical machinery and plant engineers Simulationssoftware ermöglichen heute, 

to maximise productivity, availability, safety die CAD-Daten als 3D-Produktsimulation 

and environmental tolerance over the entire in einer anschaulichen und „begreifbaren“ 

life cycle of the plants they supply. 

Darstellung in Originalgröße und Echtzeit. 

Nowadays more and more powerful com- Durch dieses „digitale Engineering im virputer 

and simulation software enables CAD tuellen Raum“ lassen sich sämtliche Anla- 

data to be presented in the form of 3D product genteile, Prozess- oder Logistiksimulationen 

simulations in a clear and ‘comprehensible’, räumlich betrachten, bis hin zum „Hinein- 

full-size and real-time representation. Thanks schauen“. In der Folge sind aufwendige 

to this ‘digital engineering in virtual space’, all Kollisions-, Funktions-, Schnittstellen- und 

plant components, process or logistics simula- Sicherheitsanalysen im Planungsstadium eftions 

can be examined in a spatial manner, as fizient durchführbar. Auch der Kunde kann 

if ‘looking into them’. Consequently, complex schon im Planungsstadium sehen, wie seine 

collision, function, interface and safety analy- Anlage funktioniert. 

ses can be carried out efficiently at the plan- Zu den zentralen Technologiefeldern 

ning stage. The customer too can see at the zählt der Energiesektor und die Mobilität – 

planning stage how his plant will work. beides Bereiche, in denen innovative Metal- 

The central technological fields include en- le als Konstruktionswerkstoff eine wesentergy 

technology and mobility – both of them liche Rolle spielen. Aluminium steht hier mit 

areas in which innovative metals play an essen- dem Werkstoff Stahl und den neuen Stahltial 

role as structural materials. In this respect sorten in fruchtbarem Wettbewerb. 

aluminium stands in fruitful competition with In vielen Marktsegmenten sind techno- 

steel and the new steel varieties. 

logischer Fortschritt und Produktinnovati- 

In many market segments technological onen eng mit dem Einsatz von Aluminium 

advances and product innovations are closely verknüpft. Aufgrund seines geringen Ge- 

associated with the use of aluminium. Thanks wichts hat sich der Werkstoff im Fahrzeug- 

to its low weight the material has now estabbau mittlerweile einen festen Platz erobert. 

lished a firm position in automotive engineer- In der Bauindustrie wird das Material wegen 

ing. In the building industry aluminium is seiner Widerstandsfähigkeit und des gerin- 

greatly valued because of its resistance and gen Instandhaltungsaufwands geschätzt. In 

low maintenance needs. In the packaging in- der Verpackungsindustrie haben sich dünne 

dustry thin strips and foils made of aluminium Bänder und Folien als gegen äußere Einflüs- 

have proved their worth as barriers against exse undurchdringliche Sperrschicht bewährt. 

ternal influences. 

Moderne Aluminiumwalzwerke sind in 

Modern aluminium rolling plants are in- komplette Fertigungsstraßen eingebunden. 

corporated in complete production lines. Cus- Gefordert werden von den Abnehmern 

tomers call for higher yields, i. e. higher rolling gesteigertes Ausbringen, das heißt höhere 

speeds, a reduction of the material thickness Walzgeschwindigkeiten, eine Verringerung 

along with improved but consistent product der Materialdicke bei verbesserter und da- 

quality by virtue of direct reaction to process bei konstanter Produktqualität durch direkte 

variations, and larger coil formats. Such aims Reaktion auf Prozessänderungen sowie grö- 

can only be achieved by perfect matching of ßere Coil-Formate. Nur über eine perfekte 

mechanical construction, hydraulic process Abstimmung von mechanischer Konstruk- 

technology and measurement and control tion, Hydraulik, Verfahrenstechnik sowie 

methods. 

Mess- und Regeltechnik lassen sich diese 

In recent years the burdening of the en- Ziele realisieren. 

vironment by metallurgical plants has been Deutlich reduziert wurde in den vergan- 

considerably reduced. Statutory provisions genen Jahren die Umweltbeeinträchtigung 

regarding emission values, water purification durch metallurgische Anlagen. Die gesetz- 

and the reduction of wastes and recycling lichen Bestimmungen hinsichtlich Emissions- 

have been the driving force for the developwerten, Wasserreinhaltung sowie Abfallrement 

of modern equipment that satisfies the duzierung und Recycling waren die Triebfe- 

specifications without problems. 

der für die Entwicklung moderner Anlagen, 

� die die Vorgaben problemlos erfüllen. � 


MEHR PRÄZISION 

BANDDICKE- 

& PROFIL 

laser-optisch mit 

thicknessCONTROL 

GESCHWINDIGKEIT 

& LÄNGE 

optisch mit 

ASCOspeed 

METEC 2011 / Düsseldorf 

28.06.2011 - 02.07.2011 

Halle 4 / Stand H35 

www.micro-epsilon.de 

Micro-Epsilon Messtechnik 

94496 Ortenburg · Tel. 0 85 42/168-0 

info@micro-epsilon.de

SMS group 


SMS group – a joint stand of 2,000 square metres 

Interesting business prospects are being 

expected by the SMS group when the 

doors open for the international trade fair 

quartet Gifa, Metec, Thermprocess and 

Newcast (GMTN). The reason: the revival 

of worldwide economic activity. The 

SMS group and the machinery and plant 

engineering sector in total have noted a 

recovery in the number of orders booked 

since the second half of 2010. 

As leading plantmakers and machine builders 

in the metallurgical and rolling mill industry, 

in tube, long product and forging as well as 

in heating technology, the companies of the 

SMS group expect to enjoy a particularly large 

share of the worldwide market recovery. By 

making strong investments and following an 

anticyclic course, SMS has made use of the 

crisis to develop new technologies, to optimise 

its plants and processes and to expand 

and modernise its own production capacities 

worldwide. This is reflected in what the SMS 

group has to offer at the GMTN trade fair. 

Under the keyword ‘Networking’, the visitors 

will experience integrated solutions from 

the SMS companies. These range from major 

integrated plant projects involving entire 

works complexes to individual machines and 

a large number of services including electrics 

and automation. In keeping with the overall 

GMNT slogan ‘The Bright World of Metals’, 

SMS is exhibiting a wide range of new and intelligent 

solutions related to the manufacture 

and processing of metals. 

A topic of major importance for the SMS 

at the fair will be environmental protection. 

Here, the group companies will be displaying 

process technologies which enable the plant 

owners to achieve long-term fulfilment of the 

ever stricter environmental protection regulations 

and, at the same time, provide economic 

benefits. In the steelmaking field, for example, 

these include recovery technologies which allow 

considerable savings to be made in energy 

costs or in raw material requirements. In addition, 

there is a whole series of further innovative 

highlights. These are being displayed on a 

‘Technology Boulevard’, using modern digital 

media, and on a total of ten large multimedia 

columns. 

Four topics especially worthy of mention 

here are: 

• The newly developed modular CSP flex 

technology allows to produce hot strip in quan- 

All companies of the group are represented on a stand measuring over 2,000 square metres in Hall 5, Stand F16. The two 

main entities are the major business areas of SMS Siemag and SMS Meer. 

tities of up to 4.0 million tpy on two thin-slab 

casting machines 

• Hydrothermal acid regeneration: this new 

type of plant with an innovatory process for 

the reconditioning of acids from pickling lines 

consumes significantly less energy and is more 

environment-friendly than previous regeneration 

plants 

• CVC 18-HS multifunctional cold rolling 

mill: this type of rolling mill can be changed 

over quickly and efficiently from a cold rolling 

mill with 18 rolls to a four-high stand for 

conventional steel grades simply by changing 

the roll cassette 

• Minimill concept for long products: in this 

concept, the SMS group companies supply all 

of the mutually harmonised components – 

from steelmaking to casting machines and further 

to the bar mill, section mill or wire-rod 

mill. 

An ample programme of lectures 

The SMS stand is of open design and invites 

dialogue. The central point of attraction of the 

joint stand is the large, transparent Conference 

Centre. ‘Transparence’ can also be taken 

here to relate to the content, because the SMS 

group companies provide a deep insight into 

the new technologies and developments when 

giving their lectures on each day of the fair. 

There is space for 120 people in the Centre. 

Each day of the fair has a different major topic: 

environmental technology, process chains, 

technologies, service and revamps. 

Anyone who misses the presence of concrete 

exhibits on the stand and would like to 

become immersed in a steelworks or rolling 

mill can experience this at the SMS group by 

means of ‘virtual reality’. The companies of 

the SMS group are making 

increasing use of computerassisted 

simulations in nearreal, 

three-dimensional effects 

in order to check complex 

plants and processes 

already at an early planning 

stage. Errors can thus be 

avoided and the technology 

optimised without expensive 

and time-consuming building 

of prototypes. These advantages 

will be presented to the 

specialist visitors with the aid 

of practical examples in the 

3-D rooms on the trade fair 

stand. 

The trade fair apps of the SMS group 

For the GMTN trade fair quartet, the SMS 

group will be providing a useful WebApp for 

smartphones and iPhones. Additionally to a 

site plan and an overview of the stands, visitors 

will receive a lot of other information, 

e. g. about the lectures given by the SMS group 

and contacts. The WebAPP can be called up 

under https://metec2011.smsgroup.com/app. 

Or use the QR code to access the WebApp. 



Achenbach – Spezialist in 

Walzwerkanlagen- und Folienschneidmaschinenbau 

Maßgeschneidertes Engineering, Eigenfertigung 

der Schlüsselkomponenten und Vormontage 

unter einem Dach in Buschhütten 

charakterisieren die starke Marke Achenbach. 

Achenbach – specialist in 

rolling mill and foil slitting machinery 

Tailor-made engineering, in-house manufacturing 

of key components and pre-assembly 

under one roof in Buschhütten 

characterise the strong brand name of 

Achenbach standing for first-class machinery 

and plant engineering ‘Made in 

Germany’: 

• Aluminium, copper and zinc rolling 

mills for all strip thicknesses and widths 

• Optiroll automation systems 

• Optifoil slitting machines for foil 

processing and for a wide range of converting 

materials 

• Optifoil separators and doublers for 

thinnest aluminium foils 

• Airpure systems for exhaust air purification 

and rolling oil recovery 

Diese steht für erstklassige Maschinen- und 

Anlagentechnik „Made in Germany“: 

• Aluminium-, Kupfer- und Zink-Walzwerke 

für alle Banddicken und Bandbreiten 

• Superstack II systems for micro-filtration of 

rolling oil 

• WOR systems for rolling oil rectification. 

Due to its broad experience in mechanical engineering 

and control technology, Achenbach 

is an appreciated partner with respect to all 

subjects concerning modernisation and service. 

The company will be exhibiting at Metec in 

Hall 4, Stand H04, ready to talk on expansion 

projects and the modernisation of production 

units as well as to inform about new developments 

on subjects like resources efficiency in 

Optipure systems, innovations in Optiroll system 

components and further developments in 

foil slitting and winding with Optifoil slitting 

machines. 

� 

SETTING THE COURSE IN ROLLING MILL MACHINERY 

• Optiroll-Walzwerkautomatisierungssysteme 

• Optifoil-Schneidmaschinen zur Weiterverarbeitung 

sowohl für Metallfolien als auch für 

ein breites Spektrum an Converting-Materialien 

• Optifoil-Separatoren und Doppler für 

dünnste Aluminiumfolien 

• Airpure-Anlagen zur Abluftreinigung und 

Ölrückgewinnung 

• Superstack II-Anlagen zur Walzölfeinstfiltration 

• WOR-Anlagen zur Walzölrektifikation. 

Durch seine große Erfahrung im Maschinenund 

Anlagenbau sowie in der Automatisierung 

ist Achenbach ein geschätzter Partner in allen 

Modernisierungs- und Servicefragen. 

Das Unternehmen stellt auf der Metec in 

Halle 4, Stand H04 aus, steht für Gespräche 

über Ausbaupläne und Modernisierungen 

von Produktionsanlagen bereit und informiert 

über Weiterentwicklungen, beispielsweise zu 

den Themen Ressourceneffizienz mit Optipure-Anlagen, 

Optiroll-Innovationen sowie 

Folienschneiden und -wickeln mit Optifoil- 

Schneidmaschinen. 

� 

TECHNOLOGY FOR FUTURE CONCEPTS 

Aluminium Rolling Mills · Heavy Metal Rolling Mills · Automation Systems · Rolling Oil Systems · Foil Slitting Machines 

28.6. - 2.7.2011 

Düsseldorf 

Hall 4 H04 

13. - 15.7.2011 

Shanghai 

Hall 7 B03 

We are looking forward to 

your visit! 

ACHENBACH BUSCHHÜTTEN GMBH 

Siegener Straße 152 · 57223 Kreuztal 

Germany · www.achenbach.de

TECHNOLOGIE 

Automatisches Langgut- und Kleinteilelager für Profilsysteme 

10.000 Langgut- und 7.000 Europaletten 

fasst das neue Hochregallager von heroal. 

Ein zentral gesteuertes Intralogistiksystem 

der Vollert Anlagenbau sorgt zwischen 

Anlieferung und Versand für einen 

reibungslosen Materialfluss. 

heroal produziert jährlich mehr als 60 Millionen 

Meter pulverlackbeschichteter Fenster-, 

Tür- und Fassadenprofile aus Aluminium. Hinzu 

kommen Profilsysteme für Rollläden, Rolltore, 

Beschattungen und Fotovoltaik. Um die 

großen Mengen effizient handhaben zu können 

und die weltweit mehr als 3.000 Kunden 

zeitnah zu beliefern, investierte das Unternehmen 

am deutschen Standort Hövelhof in der 

Nähe von Paderborn in ein komplett neues 

Logistikzentrum. Auf einer Gesamtfläche von 

60.000 Quadratmetern findet ein Hochregallager 

mit acht Gassen für Langgut und drei Gassen 

für Kleinteile sowie eine Lagerhalle mit 

20.000 Quadratmetern Platz. Die Anbindung 

der elf Regalbediengeräte an die Anlieferung 

und die Kommissionierung mit dem Versand 

übernahmen im März 2010 die Schwerlast- 

Experten von Vollert. Immerhin wiegen die 

Transportkörbe bis zu 2,3 Tonnen. 

Schwerlasttechnik auf leisen Sohlen 

Von der Anlieferung bis zum Versand läuft der 

interne Transport vollautomatisch. Lediglich 

die Kommissionierung der Kundenaufträge 

erfolgt manuell, getrennt nach Langgut und 

Kleinteilen. Großmengen werden über eine 

Bypass-Lösung kommissioniert. Da sich die 

Arbeitsplätze der Werker in unmittelbarer 

Nähe der Fördertechnik befinden, kommen 

statt Stahlrädern besonders geräuscharme 

Vulkollan-Hartgummireifen zum Einsatz. Für 

einen geringen Verschleiß sorgen extra breite 

Querschnitte. 

Der Hin- und Rücktransport der Profilkörbe 

mit den bis zu 7,2 Meter langen Aluminiumprofilen 

ist auf zwei Ebenen verteilt. Anlieferung 

und Auslagerung erfolgen im Erdgeschoss, 

die Einlagerung und die Rückführung 

leerer Transportkörbe dagegen in vier Metern 

Höhe. Ein Automatikkran vor dem Hochregallager 

bedient auf einer 60 Meter langen 

Kranbahn acht Einlagerwagen zu den Regalbediengeräten 

des Langgutlagers. Sensoren 

vermessen die Länge und Höhe der Körbe. 

Danach wählt die Steuerung automatisch den 

passenden Lagerplatz. Auch im Kleinteilelager 

erfolgt eine automatische Gewichts-, Höhen- 

und Freiraumkontrolle der Gitterboxen und 

Automated oblong and small parts 

warehouse for aluminium profile systems 

heroal’s new high-bay warehouse can 

store up to 10,000 oblong and 7,000 

euro-pallets. A centrally controlled intralogistics 

system from Vollert ensures 

optimal material flow from the point of 

receipt through to shipping. 

Every year, heroal manufactures more than 

60 million metres of powder-coated window, 

door and façade profiles from aluminium. 

Profile systems are also offered for roller 

blinds, roller doors, as well as shading and 

photovoltaic equipment. In order to handle 

the large volume of product efficiently and 

supply more than 3,000 customers worldwide 

on time, heroal invested in an all new logistics 

centre in Hövelhof near Paderborn, Germany. 

The result is a high-bay warehouse with eight 

aisles for oblong and three aisles for small 

parts, plus an additional 20,000 m 2 storage 

facility, erected on a site that spans 60,000 

m 2 . In March 2010, the company turned to 

the heavy-loads experts at Vollert to design a 

system that would link the eleven rack feeders 

from the point of receipt through to the order 

picking and shipping areas. After all, the transport 

baskets weigh up to 2.3 tonnes. 

Heavy product moves quietly 

All internal transport takes place fully automatically, 

from the point of receipt through to 

shipping. The only activity carried out manually 

is order picking, whereby a distinction is 

made between oblong and small parts. Large 

quantities are handled using a bypass solution. 

Because employees work in the direct vicinity 

of the conveyor system, a decision was made 

to substitute conventional steel wheels with 

Vulkollan hard-rubber tires, which are very 

quiet. The wheels are extra wide to keep wear 

to a minimum. 

The profile baskets, which carry aluminium 

profiles measuring up to 7.2 metres in length, 

are moved back and forth on two levels. Product 

is received and removed at ground level. 

Four metres higher, the empty baskets are 

collected and returned. An automatic crane 

was installed in front of the warehouse and 

loads eight storage cars on their way to the 

rack feeders in the aisles for oblong parts. The 

crane travels on a 60-metre track. Sensors 

measure the length and height of the baskets. 

The controller then automatically finds the 

appropriate storage bay. The small parts 

warehouse also uses an automatic weight, 

height, and clearance monitor for the lattice 

boxes and euro-pallets, which are transported 

using interconnected roller and chain conveyors. 

To avoid downtime, two hoists lower the 

pallets to be removed from the warehouse 

onto railed distribution trolleys headed to four 

picking areas. 

25,000 baskets in circulation 

The transport baskets at heroal require special 

attention, however: “Customers and sup- 


Fotos: Vollert

pliers have been using the baskets for many 

years – which number about 25,000. During 

this time, they have been jockeyed by forklifts 

and some have become misshapen as a result,” 

explains Dieter Schäfer, project manager 

at Vollert. “Buying new baskets would have 

cost more money, which is why we wanted to 

use the old ones as far as possible.” All plants 

were thus adapted to the existing system. The 

baskets also undergo a tolerance check at the 

hoist when they are received. Baskets damaged 

beyond the tolerance limit are rejected 

to ensure that the warehouse continues to operate 

smoothly. 

“Our logistics centre processes orders for 

all customers. The solution therefore had to 

be implemented on time and product relocated 

efficiently,” accentuates Ralf Meermeier, 

technical manager at heroal. This meant fully 

stocking the warehouse weeks in advance. 

“The people at Vollert did a good job, however, 

despite the truncated timetable. No delays 

were experienced and the new warehouse 

was opened at the beginning of the new year. 

Since then, we have been shipping all over 

the world from Hövelhof.” 

�� 

�� 

�� 

�� 

Europaletten, die per Rollen- und Kettenförderer 

transportiert werden und die gemeinsam 

die gleiche Fördertechnik nutzen. Um 

Standzeiten zu verhindern, senken zwei He- 

ber die Paletten zur Auslagerung auf schienengebundene 

Verteilwagen ab, die sie auf vier 

Kommissionierplätze verteilen. 

25.000 Körbe im Umlauf 

Eine Besonderheit stellen die Transportkörbe 

von heroal dar. „Seit vielen Jahren sind diese 

bei Kunden und Lieferanten im Umlauf – 

insgesamt etwa 25.000 Stück – und durch 

den manuellen Staplerbetrieb teilweise verformt“, 

erklärt Projektleiter Dieter Schäfer 

von Vollert. „Trotzdem wollten wir die Körbe 

aus Kostengründen natürlich beibehalten.“ 

Alle Anlagen wurden dazu auf das bestehende 

System abgestimmt. Zusätzlich erfolgt im 

Vollkorbheber bei der Anlieferung eine Toleranzmessung. 

Zu stark verformte Körbe werden 

ausgeschleust. Damit ist ein störungsfreier 

Betrieb des Lagers sichergestellt. „Da unser 

Logistikzentrum die gesamte Kundenbelieferung 

übernimmt, waren die termintreue Fertigstellung 

und ein reibungsloser Lagerwechsel 

�� 

�� 

�� 

�� 

�� 

�� 

�� 

�� 

TECHNOLOGY 

für uns sehr wichtig“, betont Ralf Meermeier, 

technischer Leiter bei heroal. Dazu musste das 

Lager bereits Wochen zuvor komplett befüllt 

werden. „Aber die Kollegen von Vollert haben 

gute Arbeit geleistet – trotz der kurzen Realisierungszeit. 

Ohne Verzögerungen konnten 

wir das neue Lager zum Jahreswechsel starten 

und seitdem beliefern wir von Hövelhof aus 

die gesamte Welt.“ 

� � 


TECHNOLOGIE 

S + C Extrusion Tooling Solutions 

Vom ehemaligen Stahllieferanten 

zum kompetenten Partner für Rezipienten 

Seit September 2009 wird das Strangpressgeschäft 

der Schmidt + Clemens 

Gruppe von der S+C Extrusion Tooling 

Solutions GmbH (ETS) mit Sitz in Lindlar 

wahrgenommen. Die neue Gesellschaft ist 

ganz auf die Bedürfnisse der Strangpresslieferanten 

und -betreiber spezialisiert. 

Im Kern geht es um die Konstruktion und 

den Bau der Werkzeuge, insbesondere 

der Rezipienten, sowie um Serviceangebote 

wie beispielsweise Umbüchsen. 

Das frühere Standbein Schmelzen und 

Schmieden der Werkzeugstähle ist heute 

in den Händen von spezialisierten 

Lieferanten, mit denen man eng zusammenarbeitet. 

ETS-Geschäftsführer Olaf 

Müller erläutert im Gespräch mit dieser 

Zeitschrift: „Natürlich verfügen wir nach 

wie vor über ein umfassendes Werkstoff-Knowhow 

und entwickeln dieses 

kontinuierlich weiter. Mit der vor einigen 

Jahren begonnenen Neuausrichtung 

vom ehemaligen Stahllieferanten zum 

S + C Extrusion Tooling Solutions 

Once a steel supplier, now a 

competent partner for containers 

Since September 2009 the extrusion business 

of the Schmidt + Clemens group 

has been looked after by S + C Extrusion 

Tooling Solutions GmbH (ETS) with its 

headquarters in Lindlar, Germany. The 

Werksgelände der S+C Group in Lindlar S+C production site in Lindlar, Germany 

new company specialises entirely in the 

needs of extrusion press suppliers and 

operators. The focus is on the design and 

construction of the tools, in particular 

containers, and on the provision of services 

such as relining. The previous main 

activity of melting and forging tool steels 

is now in the hands of specialist suppliers 

with whom close collaboration is 

maintained. ETS executive director Olaf 

Müller explained in a discussion with this 

journal: “Naturally we still have compre- 

hensive know-how about materials and 

are continually developing this further. 

But with the reorientation we started a 

few years ago, from a one-time steel supplier 

to a competent partner for tools and 

solutions, we have at the same time provided 

the basis for meeting the needs of 

our customers flexibly and individually.” 

This customer orientation is reflected in intensive 

and continual consultancy, from the first 

inquiry about a project right up to the end of 

the product life of a container. For example, 

this advisory competence extends to selecting 

the container material in accordance with the 

alloy to be extruded, to how the container 

should be designed depending on the customer’s 

production practice, to how the container 

is to be heated, and what heating elements 

should be used for this. 

The extrusion business of ETS is not limited 

to the aluminium industry but also includes 

the sector of heavy and copper-base metals and 

the extrusion of steels and special alloys used 

for example in aerospace. At ETS specialists 

in all of these technical fields are available. 

The aluminium division includes new tooling 

business for extrusion press manufacturers 

and for the end customers as well. Another 

important pillar is the restoration of containers 

to the latest state of the art by relining. 

Classically, a container consists of the mantle, 

the intermediate and inner lining, and a 

heating and cooling system. These components 

undergo a certain amount of wear. This applies 

particularly to the inner lining which, throughout 

the extrusion process, is in contact with 

the extrusion billet at its extrusion temperature 

and is subjected to load levels that vary 

depending on the extrusion method, pressure, 

temperature, extrusion sequence and extrusion 

duration. “The inner lining must therefore 

be adapted individually to the extrusion 

programme. By virtue of our designs, based 

for example on FEM calculations and thermal 

analyses, our containers have a very long life. 

Nevertheless, depending on the throughput 


Abbildungen: S+C Schmidt + Clemens

and the alloys used, the inner linings have to 

be changed at regular intervals,” explains Mr 

Müller. If the customer so wishes, the inner 

linings can also be stocked by S + C so that the 

container can be used again as soon as possible 

in the customer’s production. 

Until now maintenance and repair work 

has been carried out in Lindlar. “With our 

Videoscope system we then conduct investigations 

on the tool and carry out a 

comprehensive heating check,” Mr 

Müller says. With the Videoscope 

system the channels and bores are 

checked so as to alert the customer 

early about any small cracks and 

weak-points, and to estimate the 

remaining life to be expected. The 

tool as a whole is thoroughly inspected 

and finally sent back to the 

customer with full documentation. 

This year a new servicing centre will 

start operating in China. 

In general the company’s motto 

is: Stay close to the customer, get to 

know his process in detail and communicate 

with all those involved at 

the same technical level, from machine 

operators, to technical staff, 

right up to management level. “That 

is what we perceive as our special 

market position,” he says. 

Specialisation in tool solutions 

Until a few years ago the business of S + C 

also included the production of high-alloy tool 

steels. “At that time we had to sell a lot of steel 

in a short time in order to keep our capacities 

occupied sufficiently. Our business included 

melting, forging and the entire subsequent finishing 

chain from heat treatment to machining. 

Today we concentrate on consultancy about 

kompetenten Partner für Werkzeuge und 

Lösungen haben wir aber zugleich die Basis 

geschaffen, den Bedürfnissen unserer 

Kunden flexibel und individuell gerecht 

zu werden.“ 

Diese Kundenorientierung spiegelt sich in einer 

intensiven und kontinuierlichen Beratung 

von der ersten Projektanfrage bis hin zum 

Ende des Produktlebens eines Rezipienten 

wider. Die Beratungskompetenz erstreckt 

sich beispielsweise auf die Werkstoffauswahl 

beim Container in Abhängigkeit von der zu 

verpressenden Legierung, wie der Container 

in Abhängigkeit von der Produktionsweise 

des Kunden auszulegen ist, wie er aufzuhei- 

zen ist und welche Heizelemente dafür verwendet 

werden. 

Das Strangpressgeschäft der ETS ist nicht 

TECHNOLOGY 

auf die Aluminiumindustrie beschränkt, sondern 

umfasst auch den Bereich der Schwer- 

und Buntmetalle, die Stahlextrusion und Sonderlegierungen 

zum Beispiel in der Luft- und 

Raumfahrt. Für all diese Fachgebiete stehen 

bei ETS jeweils zugewiesene Spezialisten bereit. 

Die Aluminiumsparte umfasst das Werkzeug-Neugeschäft 

für den Strangpressenbauer 

wie für den Endkunden. Ein wichtiges weiteres 

ETS-Strangpresswerkzeuge ETS extrusion tools 

Standbein besteht darin, die Container über 

Umbüchsarbeiten wieder arbeitstechnisch auf 

den neuesten Stand zu bringen. 

Ein Container besteht klassischerweise aus 

Mantel, Zwischen- und Innenbüchse sowie 

aus einem Heiz- und Kühlsystem. Diese 

Komponenten unterliegen einem gewissen 

Verschleiß. Das gilt insbesondere für die Innenbüchse, 

die während des gesamten Pressvorgangs 

mit dem auf Presstemperatur be- 


TECHNOLOGIE 

findlichen Pressbolzen in Berührung kommt 

und je nach Pressverfahren, Pressdruck, 

Presstemperatur, Pressfolge und Pressdauer 

unterschiedlich hoch beansprucht wird. „Diese 

Innenbüchse muss daher individuell an das 

Pressprogramm angepasst werden. Durch 

unsere Auslegung beispielsweise über FEM- 

Berechnungen und über thermische Analysen 

haben unsere Container eine sehr hohe Lebensdauer. 

Dennoch muss die Innenbüchse in 

Abhängigkeit vom Durchsatz und der eingesetzten 

Legierungen regelmäßig ausgetauscht 

werden“, erklärt Müller. Diese Innenbüchsen 

werden auf Kundenwunsch auch von S+C bevorratet, 

damit der Container schnellstmöglich 

wieder in der Produktion des Kunden 

eingesetzt werden kann. 

Wartungs- und Reparaturarbeiten werden 

bislang in Lindlar durchgeführt. „Dann nehmen 

wir mit unserem Videoscope-System Un- 

tersuchungen am Werkzeug vor und führen 

eine umfassende Heizungskontrolle durch“, 

erläutert Müller. Mit dem Videoscope-System 

werden die Kanäle und Bohrungen überprüft, 

um die Kunden frühzeitig auf kleine Risse 

und Schwachstellen hinzuweisen und die zu 

erwartende Lebensdauer abzuschätzen. Das 

gesamte Werkzeug wird eingehend inspiziert 

und schließlich mit einer Dokumentation an 

den Kunden zurückgeschickt. In China wird 

noch in diesem Jahr ein neues Servicecenter 

in Betrieb genommen. 

Generell heißt die Devise: Nahe am Kunden 

sein, seine Prozesse im Detail kennen, 

mit allen Beteiligten vom Maschinenbediener 

über den Techniker bis zur Geschäftsführung 

auf gleicher Fachebene kommunizieren. 

„Darin sehen wir unsere besondere Marktstellung“, 

so Müller. 

Spezialisierung auf Werkzeuglösungen 

Bis vor einigen Jahren umfasste das S + C- 

Geschäft auch die Herstellung von hochle- 

gierten Werkzeugstählen. „Damals musste 

man viel Stahl in kurzer Zeit verkaufen, 

um Kapazitäten umfassend auszulasten. Unser 

Geschäft umfasste das Schmelzen und 

Schmieden und die gesamte nachfolgende 

Veredelungskette von der Wärmebehandlung 

bis zur Zerspanung. Heute konzentrieren wir 

uns auf die Werkstoff- und Prozessberatung 

und haben so mehr Freiheiten, uns auf das 

Komponentengeschäft mit hoher Wertschöpfung 

zu konzentrieren. Für die vorgelagerten 

Produktionsstufen arbeiten wir mit ausgesuchten 

Schmelz- und Schmiedepartnern 

zusammen, die unserem Qualitätsdenken entsprechen 

und in diesem Geschäftsfeld für uns 

tätig sind“, sagt Müller. 

Die Spezialisierung auf Werkzeuglösungen 

hat sich für ETS ausgezahlt. Im vergangenen 

Jahr konnten wichtige Neuprojekte akquiriert 

werden. Außerdem gewann ETS einen 

Großauftrag vom weltweit führenden Strangpressenbauer 

SMS Meer, der die komplette 

Erstausrüstung von insgesamt 16 Aluminium- 

Strangpressen für zwei namhafte chinesische 

Endkunden vorsieht. Dies umfasst verschiedene 

Container für Strangpressen mit einer 

Presskraft zwischen 11 und 150 MN. Container 

für eine 150-MN-Großpresse gehören 

zweifellos zu den ultimativen Highend-Produkten, 

die für einen Werkzeughersteller eine 

herausragende Referenz darstellen. Entsprechend 

stolz ist man bei ETS, für diesen Auftrag 

den alleinigen Zuschlag erhalten zu haben. 

Was zeichnet einen Blockaufnehmer heute 

gegenüber Produkten vor zehn Jahren aus? 

„Wir verfügen heute werkstoffkundlich über 

ein vervielfachtes Fachwissen und können 

über entsprechende Rechenmodelle die Container 

viel präziser auslegen“, sagt Müller. 

„Die Container sind zudem mit deutlich verbesserten 

Heizpatronen ausgestattet, sowohl 

in der Standardausführung als auch über 

das neu entwickelte COP-Cartridge-System 

(COP = Container Overheat Prevention), 

materials and processes, and so have greater 

freedom to focus on component business with 

higher value addition. For the upstream production 

steps we work together with selected 

melting and forging partners who subscribe to 

our quality concepts and act for us in this area 

of business,” Mr Müller explains. 

This specialisation in tool solutions has paid 

dividends for ETS. Last year a number of important 

new projects were acquired. In addition, 

ETS was awarded a major contract from 

the world-leading extrusion press manufacturer 

SMS Meer, which involves the complete 

initial equipping of a total of 16 aluminium 

extrusion presses for two noted Chinese end 

customers. This includes various containers 

for presses with extrusion loads between 11 

and 150 MN. Containers for a 150-MN large 

press undoubtedly represent the ultimate 

high-end products and constitute an outstanding 

reference for a tool manufacturer. At ETS 

great pride is taken in being the only approved 

supplier for this contract. 

What distinguishes a billet container today 

compared with the products of a decade 

ago? “Nowadays we know very much more 

about materials science and can design containers 

much more precisely with the help 

of appropriate computer models,” Mr Müller 

says. “Moreover, the containers are fitted with 

greatly improved heating cartridges, both in 

the standard version and in the form of the 

newly developed COP-Cartridge system 

(COP = Container Overheat Prevention), in 

which a thermocouple is built into the heating 

cartridge. This has been patented by our 

exclusive partner IAS, with whom there is also 

an agreement that ETS is the only container 

manufacturer in Germany licensed to incorporate 

this product.” 

Containers have to be heated to their working 

temperature in a very controlled manner 

to avoid producing any thermal stresses in 

the system. Extrusion should not be carried 

out below a certain temperature level since 

the hot-working steel is then not yet at temperature 

and cracks can be produced. Heating 

takes place in defined steps per unit time, with 

equalisation intervals between them. In addition 

there must be a balance between heating 

or controlled cooling during the extrusion 

process itself, to prevent the container from 

softening due to an annealing effect. Heat 

sensors send the corresponding measurement 

data to the control system of the heating and 

cooling processes. “Since with the COP-Cartridge 

system the thermocouple is built into 

the heating cartridge itself, the heat is measured 

exactly where it is produced. In this way 

the heating of the container can be controlled 


with pin-point accuracy,” he stresses. 

Material technology in relation to the 

extruded alloys has also developed further. 

The property profile required for materials is 

continually becoming more demanding, and 

compared with past years the geometry of extruded 

sections is often much more complex. 

“This brings one very quickly to the high-end 

range of the tools, tools steels and extrusion 

presses used,” he says. 

Extending the 

internationalisation of the business 

Most of all in Central Europe many extrusion 

plants have specialised in the production of 

demanding extruded products. It is therefore 

hardly surprising that Europe is still a core 

market for ETS. Germany and some other European 

countries have a high density of very 

expert mechanical engineering companies, 

including many extrusion plants which set a 

high value on quality and compliance with 

delivery deadlines. “With our expertise, this 

is where we find that people listen to us, where 

our consultancy-intensive and complex con- 

bei dem ein Thermoelement in der Heizpatrone 

eingebaut ist. Dabei handelt es sich um 

ein Patent unseres Exklusivpartners IAS, mit 

dem eine Vereinbarung darüber besteht, dass 

ETS als einziger deutscher Rezipienten-Hersteller 

dieses Produkt einbauen darf.“ 

Das Aufheizen eines Containers auf Arbeitstemperatur 

muss sehr kontrolliert erfolgen, 

damit keine Thermospannungen im 

System entstehen. Unter einem gewissen Temperaturniveau 

sollte nicht stranggepresst wer- 

den, weil der Warmarbeitsstahl dann noch 

nicht auf Temperatur ist und Risse entstehen 

können. Das Aufheizen erfolgt in definierten 

Schritten pro Zeiteinheit und dazwischen liegenden 

Phasen der Egalisierung. Außerdem 

kommt es auf die Balance von Heizen oder 

dosierter Kühlung während des Pressvorgangs 

an, damit der Container nicht weichglüht. 

Thermofühler geben die entsprechenden 

Messdaten zur Steuerung der Heiz- und 

Kühlvorgänge. „Da das Thermoelement beim 

COP-Cartridge-System in der Heizpatrone 

eingebaut ist, wird die Wärme exakt da gemessen, 

wo sie entsteht. Auf diese Weise kann 

man die Erwärmung des Containers punktge- 

TECHNOLOGY 

nau steuern“, betont Müller. 

Auch die Werkstofftechnik hinsichtlich der 

verpressten Legierungen hat sich weiterentwickelt. 

Die geforderten Eigenschaften an die 

Werkstoffe werden immer anspruchsvoller, 

die Profile weisen gegenüber früheren Jahren 

vielfach komplexere Geometrien auf. „Da 

ist man sehr schnell im Highend-Bereich der 

eingesetzten Werkzeuge, Werkzeugstähle und 

Strangpressen“, so Müller. 

Internationalisierung des 

Geschäftes wird ausgebaut 

Besonders in Mitteleuropa haben sich viele 

Presswerke auf anspruchsvolle Strangpressprodukte 

spezialisiert. Daher verwundert es 

nicht, dass Europa weiterhin ein Kernmarkt für 

ETS ist. Deutschland und andere europäische 

Länder weisen eine hohe Dichte sehr qualifizierter 

Maschinenbau-Unternehmen auf; hier 

sitzt eine Vielzahl von Strangpresswerken, 

die hohen Wert auf Qualität und Liefertermintreue 

legen. „Hier finden wir mit unserer 

Expertise ein offenes Ohr, hier werden unsere 

beratungsintensiven und komplexen Contai

TECHNOLOGIE 

ner auch preislich honoriert“, sagt Müller. 

Neben Europa gewinnt auch der chinesische 

Markt für ETS an Bedeutung. Das zeigen 

nicht zuletzt die oben skizzierten Container- 

Aufträge für chinesische Endkunden und der 

erwähnte Aufbau 

einer Servicegesellschaft 

für 

Strangpresswerkzeuge 

in China. 

Derzeit baut ETS 

den lokalen Vertrieb 

in China weiter 

aus. 

Sowohl für den 

chinesischen wie 

für den nordamerikanischen 

Markt 

werden laut Müller 

derzeit zahlreiche 

Umbüchsarbeiten 

durchgeführt. Mit 

Blick auf Russland 

sieht er sich ebenfalls 

gut aufgestellt. 

„Neben einer guten 

Vertretung vor 

Ort haben wir bei 

uns im Haus auch 

einige Muttersprachler.“ 

Die Internationalisierung 

des 

ETS-Geschäftes erfährt klare Unterstützung 

seitens der S + C-Gruppe. Im jüngst veröffentlichten 

Geschäftsbericht heißt es, die Stärkung 

kleinerer Gesellschaften wie ETS zu einem 

ausbaufähigen Standbein sei „ein wesentliches 

Anliegen der Geschäftsführung“. 

Als Spätzykliker ist das ETS-Geschäft erst 

in den letzten Monaten deutlicher aus der Talsohle 

der Wirtschaftskrise herausgekommen. 

Mit Blick auf das erste Quartal dieses Jahres 

habe die Anfragetätigkeit spürbar zugenommen, 

„die Umsetzung ist jedoch noch ausbaufähig“, 

so Müller. Für 2011 rechnet er jedoch 

mit einer Belebung der Investitionen in den 

Kernmärkten des Unternehmens. 

Auf die Frage, welche strategischen Aufgaben 

sich ETS für die kommenden Jahre 

setzt, um die Marktposition zu festigen und 

auszubauen, antwortet Müller kurz und 

knapp: „Wir arbeiten an der permanenten 

Optimierung der internen Prozesse, an der 

Pflege und dem Ausbau unseres Lieferantennetzwerkes 

und werden weiter in moderne 

Produktionsmethoden investieren – um auf 

diese Weise unseren Kunden einen größtmöglichen 

Mehrwert zu bieten.“ 

� 

tainers are deemed worth their price,” says 

Mr Müller. 

Besides Europe, the Chinese market is also 

gaining importance for ETS. Not least, this is 

shown by the container contracts for Chinese 

Detailansicht eines Rezipienten Detailed view of a container 

end customers outlined earlier, and the setting 

up of a servicing company for extrusion plants 

in China, as mentioned. At present ETS is extending 

its on-the-spot sales in China. 

According to Mr Müller, in both the Chi- 

In 2010 Schmidt + Clemens slightly increased 

its consolidated turnover to 233 million euros 

(+ 2.2%). Overall, the management rated the 

past year as solid and the result achieved as very 

positive. After the downturn in 2009, however, 

revenues have not recovered significantly. “In 

2010 the markets lagged behind expectations. 

Yet, we are satisfied with the results achieved 

by the S +C group. Our business always develops 

late in a cycle,” said Henning Kreisel, CFO of the 

company group. Managing partner Jan Schmidt- 

Krayer also views the future with optimism: 

“Since the second half of 2010 we have noted a 

revival of the markets and this trend has continued 

in the first quarter of 2011. On the whole, 

we are relatively busy.” 

nese and North American markets numerous 

relining projects are currently taking place. 

Looking at Russia, he also feels well set up: 

“Besides good local representation, we also 

have a few native Russian speakers in our 

company.” 

The internationalisation of ETS’s 

business is receiving good support 

from the S + C group. In the recently 

published annual report it is stated 

that reinforcing smaller companies 

such as ETS to help them become 

pillars capable of expanding on 

their own is “an essential concern 

of the management”. 

ETS’s business always develops 

late cyclical, so only in recent 

months it has emerged more clearly 

from the economic crisis. Looking 

at the first quarter of this year, business 

interest has increased appreciably 

“but implementation is not yet 

self-sustaining,” says Mr Müller. 

For 2011, however, he anticipates 

a revival of investment in the core 

markets of the company. 

On the question of what strategic 

objectives ETS is setting itself 

for the coming years in order to 

strengthen and extend its market 

position, Müller’s answer is concise: 

“We are working on the continual 

optimisation of internal processes, 

on the care and extension of our supplier network, 

and we plan to invest more in modern 

production methods in order, in this way, to 

offer our customers the greatest possible added 

value.” 

� 

S + C achieves a positive balance for 2010 

Schmidt + Clemens is a leading producer of 

special steel components. The group’s chief 

markets are petrochemistry, separation technology, 

power engineering, the pump industry and 

extrusion and rolling technology. The group 

employs around 1,000 people worldwide, about 

600 of them in Germany. Apart from the parent 

plant in Germany the group also has production 

facilities in Brazil, Spain, the UK, the Czech 

Republic, Malaysia and Saudi Arabia. In addition 

to spun castings the group also produces mould 

castings. Forgings for the extrusion industry and 

for plant and mechanical engineering round 

off the product range. Rolls for the most varied 

fields of application are produced by the British 

subsidiary S + C Bowers & Jones Ltd. 


Presezzi Extrusion 

Success for Presezzi Extrusion in USA 

The Nanshan Group, one of the China’s leading aluminium 

extrusion companies, has chosen Presezzi Extrusion S.p.A. 

to supply a 45-MN extrusion press with piercer for its first 

US manufacturing facility in Lafayette, Indiana. The stateof-the-art 

press is destined for a new plant that will produce 

hard alloys and specialty profiles. According to Nanshan, 

the new plant will have four extrusion lines once it is completed. 

The company sees this order as confirmation of its 

position as the leading foreign company for sales of extrusion 

presses in America. 

Bruno Donada, area manager at Chicago-based Presezzi Extrusion 

North America, explains why Nanshan has placed the order 

with his company: “The 

finished profiles and 

tube will be made from 

special aluminium alloys 

and need to be accurate. 

Coupled with the demands 

that will be made 

on the extrusions, this 

means that one has to 

have an extrusion press 

in which the die and all 

those parts of the press 

that are subjected to high 

loads exhibit very high 

dimensional accuracy 

Bruno Donada, area manager at 

Presezzi Extrusion North America 

and maintain their shape. 

They also have to reliably 

control the centring 

system and the operat- 

ing temperatures. For other projects where similar high demands 

were placed on performance, Presezzi Extrusion’s R & D department 

has already exhaustively examined and tested a groundbreaking 

system for centring and retaining the working axis during 

the extrusion process. A thorough analysis of this system by the 

customer’s technical evaluation committee led to it being awarded 

high marks for technical merit. This was undoubtedly a contributory 

factor to Presezzi Extrusion receiving the order.” 

Mr Donada also points to the company’s total quality manage- 

Suppliers Directory – 

for your benefit 

On pages 100 to 113, leading 

equipment suppliers to the aluminium 

industry present their product portfolios 

and ranges of services. Take advantage 

of this useful information. 

TECHNOLOGY 

ment (TQM) system and its commitment to manufacturing plant and 

equipment that is of the highest technical standard. “If we play this 

trump card, we are rewarded with such sales and meet with the approval 

of our customers here abroad as well,” he adds. Today, Presezzi 

Extrusion’s customers in the USA are being forced to invest in plant 

that allows an optimum balance to be struck between costs, efficiency 

and energy savings in order to achieve success in the marketplace. With 

regards to the great importance now being attached to energy efficiency, 

Mr Donada referred to a system for saving energy that has been patented 

by the company and installed on almost all Presezzi machines for the 

past two years. “This system enables our customers to achieve electrical 

energy savings of 20 to 25 percent,” he stresses. 

When asked about an effective customer service set-up for the US 

market, he points out that Presezzi Extrusion has opened up a subsidiary 

in Chicago that guarantees quick and optimal customer support. “However, 

I would also like to draw attention to the remote maintenance and 

black-box system that we install on all of our machines; this enables us 

to continuously monitor possible technical faults around the clock from 

our headquarters in Italy, and rectify them immediately. This means 

that almost no intervention on site is needed anymore,” he says. 

Developments in the American market appear to be positive for 

Pressezzi Extrusion. It is involved in various projects and some of these 

are expected to announce a final decision shortly. 

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Aluminium 

smelting industry 

GIIG and Chinalco to build 

aluminium smelter in Malaysia 

Gulf International Investment Group (GIIG) 

Holdings Sdn Bhd and UAE-based business 

leader Mohamed Alabbar have entered into a 

joint venture agreement with Aluminium Corp. 

of China (Chinalco) to develop a USD1.6bn 

aluminium smelter in the State of Sarawak, 

Malaysia. Smelter Asia Sdn Bhd will develop, 

own and operate the private aluminium plant 

with a production capacity of 370,000 tpy 

during the first phase. On further availability 

of power from the grid, the plant capacity is 

planned to be increased up to 700,000 tonnes. 

The smelter will be located in Samalaju Industrial 

Park, about 60 km from Bintulu. 

Alongside the signing of the JV agreement, 

Smelter Asia also executed the principal terms 

of the Power Purchase Agreement (PPA) with 

Syarikat Sesco Berhad, the wholly owned subsidiary 

of Sarawak Energy Berhad, for over 

600 MW of power supply to the proposed aluminium 

smelter. Both companies will jointly 

conclude the PPA by the middle of this year. 

GIIG is headed by Malaysian tycoon Tan 

Sri Syed Mokhtar Al-Bukhary who said: “The 

global demand for aluminium is projected to 

grow by an average 4% over the next five 

years, with Asia driving the demand. Our strategic 

collaboration with Chinalco for Smelter 

Asia will bring the best-in-class technology 

to create a modern aluminium plant that will 

Norsk Hydro 

contribute to the socio-economic growth of 

Sarawak state. The plant will create new jobs 

and drive the growth of supporting industries, 

thus contributing significantly to the development 

of the state of Sarawak as well as the 

Malaysian economy.” 

The Smelter Asia plant will have a strategic 

location within the Score corridor of the 

State of Sarawak, where the availability of 

world-class infrastructure, port facilities and 

proximity to the fast growing markets will enable 

the company to timely meet the demand 

for aluminium from global markets. Smelter 

Asia is committed to be amongst the low-cost 

producers and a significant player in the aluminium 

industry in all areas including health, 

safety and environment (HSE) and its corporate 

social responsibilities. 

Emal signs further 

liquid metal contracts 

Emirates Aluminium (Emal) has signed two 

new liquid metal contracts with local companies 

based next to the Taweelah based smelter, 

in the Khalifa Industrial Zone Abu Dhabi. 

One of these companies is Trans Gulf, a local 

manufacturer of aluminium wire rods and alloy 

ingots. Trans Gulf will receive 50,000 to 

80,000 tpy of molten aluminium. Contracts 

like these ensure that Emal remains on track 

to fulfill the ambitious targets in its business 

plan. They also contribute that the smelter continues 

to grow as the UAE’s most significant 

non-oil and non-gas industrial project. Growth 

beyond the energy sector is a key element of 

On the move 

After the departure of Roger Agnelli, Vale’s main 

shareholder, Valepar nominated Murilo Pinto de 

Oliveira Ferreira as the company’s new CEO. 

Alcoa announced that Ray Kilmer, currently 

vice president, Technology Development and Deployment, 

has been appointed chief technology 

officer, succeeding Mohammad Zaidi, who will 

retire. Kilmer will become a member of Alcoa’s 

executive council and will be recommended to 

be elected an officer of the company by Alcoa’s 

board of directors. 

Alcoa has named Dina Shapiro director, Marketing 

Communications and Branding, responsible 

for driving an integrated marketing strategy 

across the company’s businesses for and enhancing 

Alcoa’s iconic brand around the world. 

UC Rusal appoints Igor Makarov chief legal 

officer. He will be responsible for the comprehen- 

the UAE’s 2030 Vision to develop a sustainable 

economic future for the country. 

Alcoa output to increase 

50,000 tonnes in Q2 

Alcoa will produce an additional 50,000 

tonnes of primary aluminium in the second 

quarter, as restarts at three US smelters gain 

traction. The restarts include potlines at the 

company’s Massena East smelter in Massena/New 

York, Wenatchee Works in Malaga/ 

Washington and Intalco Works in Ferndale/ 

Washington. The move will lead to some 

200,000 tpy of additional output. The restarts 

have cost Alcoa some USD9m, but all three 

plants are expected to be profitable in Q2, 

even as raw material costs continue to rise. 

Alcoa also is expecting to increase alumina 

production in the second quarter. The company’s 

primary aluminium output totalled 

904,000 tonnes in the first quarter, while alumina 

output was down slightly to 4m tonnes. 

China toughens line 

on new smelter projects 

China has ordered a stop to approvals for 

new aluminium smelters, marking a fresh and 

apparently tougher push to rein in rapid expansion. 

Central and provincial governments 

should stop approving construction of new 

smelters, according to a statement published 

on a government website and attributed to 

nine ministries and departments. 

The central government wants provincial 

sive legal support of the company’s operations 

to minimise risks through the best international 

practices. Kirill Alexandrov, who was heading the 

legal practice at Rusal, becomes the director of 

legal at En+ group of companies. 

Aluminum Association president Steve Larkin 

will retire at the end of 2011 after 13 years in the 

post. 

Adel Ghuloom Al Mansoori is the new manager 

of Alba’s Carbon Maintenance Department. 

UC Rusal appointed Ekaterina Nikitina director 

of Human Resources. Victoria Petrova, who 

was heading the HR function at Rusal, becomes 

deputy CEO responsible for human resources 

management at Basic Element. 

Richard G. Holder, former chairman of Reynolds 

Metals Co. and the Aluminum Association, 

died at the age of 79. 


governments to cancel some incentives offered 

to companies building new aluminium 

smelters. China’s government is targeting aluminium 

expansions in order to prevent overproduction, 

but more importantly as part of 

an effort to tighten controls over energy-intensive 

industries. Nationwide aluminium 

capacity could reach 30m tpy by 2015 if 23 

currently planned projects proceed. 

Alcoa to invest in Quebec plants 

Alcoa Global Primary Products Canada 

plans to invest about C$100m 

in its four Quebec plants this year 

as it looks to capture some of the 

anticipated 12% increase in global 

aluminium demand in 2011. About 

half of the investment will go toward 

operational maintenance, with another 

C$25m earmarked for health 

and safety, C$14m for cost-reduction 

projects and the remainder for 

environmental and energy efficiency 

efforts. More than 80 projects will 

be completed throughout the year. 

Included in the operational maintenance 

activities will be the replacement 

of the Deschambault smelter’s 

No. 1 transformer at a cost of US- 

D12m, and the busbars that redirect 

electric current to electrolytic cells 

at Deschambault will be enhanced 

through a new cooling mechanism. 

In addition, the smelters in Baie- 

Comeau, Deschambault and Bécancour 

will see the implementation of 

innovative computer-based cell control 

systems offering enhanced reliability. 

A new series of stubs used to 

distribute current through anodes at 

the Baie-Comeau smelter will now 

have the capacity to be straightened 

and reused, which will help achieve 

more efficient and sustainable processes 

in the long term. 

Aluminium surplus 

rises in early 2011 

Primary aluminium was in a 

302,000-tonne surplus in the first 

two months of 2011, according to 

data released by the World Bureau 

of Metal Statistics (WBMS). This 

compares with a 247,000-tonne surplus 

in the first two months of 2010. 

In Jan/Feb 2011, demand for pri- 

mary aluminium hit 6.46m tonnes (+103,000 

t) while production rose by 158,000 tonnes 

(+2.4%). In the EU, production rose by 10% 

while demand increased by 13% in the first 

two months of the year compared with the 

same period in 2010. Total stocks of primary 

aluminium came in at 6.92m tonnes at the 

end of February, enough for 63 days demand. 

This was up from 6.5m tonnes at the end of 

2010. The London, Shanghai, USA and Tokyo 

exchanges reported total stocks of 5.31m 

tonnes by the end of February, 6.7% above 

the December 2010 total. Global producer 

stocks at the end of February was 1.52m. � 


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Bauxite and 

alumina activities 

Antam starts to build 300,000 tpy 

chemical grade alumina plant 

Indonesia’s PT Aneka Tambang (Antam) has 

started the construction of a 300,000 tpy 

chemical grade alumina (CGA) plant in Tayan, 

West Kalimantan province of Indonesia. The 

USD450m Tayan CGA project will be developed 

by PT Indonesia Chemical Alumina 

�� 

For over 50 years BUSS KE and CP series Kneaders have been 

the benchmark for reliable, cost-effective compounding of 

anode pastes. Now we go one step further. 

Hall E7 

Stand 7H07 



(ICA), a joint venture company between Antam 

and Showa Denko K.K. of Japan. Antam 

owns 80% of ICA and Showa Denko holds the 

remaining 20%. Construction of the project is 

expected to take 32 months, and commercial 

production is expected to commence in January 

2014. 

The Tayan CGA Project will process Antam’s 

bauxite reserves to produce 300,000 tpy 

of CGA. This will be exported as well as sold to 

the Indonesian domestic market. Antam mines 

bauxite, and is eyeing a stake in Indonesia’s 

only aluminium smelter, Indonesian Asahan 

Aluminum (Inalum), with the intention of integrating 

its aluminium business from the very 

upstream to the downstream. 

Orbite to process rare earths 

at Canadian alumina plant 

Montreal-based alumina start-up Exploration 

Orbite VSPA Inc. expects to produce a number 

of rare earth and minor metal oxides as by- 

products when it brings its planned metallurgi- 

cal alumina facility online in 2013. The company, 

which plans to produce alumina by 

processing aluminous clay rather than traditional 

bauxite, will also make gallium, scandium 

and rare earth oxides at its Quebec facility. 

The decision to process and sell the oxides 

was triggered by a discovery that the company’s 

Grande-Vallée aluminous clay deposit 

contains high levels of gallium and scandium, 

as well as detectable levels of dysprosium, lanthanum, 

neodymium, praseodymium and yttrium. 

Orbite’s planned alumina plant, which 

will eventually process 7,000 tonnes of aluminous 

clay per day, will also produce ‘tens and 

hundreds of kilograms’ of rare earth oxides 

daily for sale to third-party consumers. The 

plant’s 1,750 tpd alumina output is up from 

previous estimates of about 750 tpd. 

Nalco starts up 525,000 tpy 

alumina expansion at Damajjodi 

India’s National Aluminium Co. (Nalco) has 

begun commissioning a new alumina refinery 

in Orissa, bringing the company’s capacity to 

2.1m tpy. The 525,000 tpy plant is the second 

phase of an expansion at Damanjodi in eastern 

Orissa, which was delayed in April 2009. The 

company has already placed orders for new 

equipment to raise capacity again, to more 

than 2.27m tpy. Earlier, Potline 4 of Nalco’s 

smelter and the units 9 and 10 of its captive 

power plant, both located at Angul, were commissioned. 

The work at the refinery in Daman- 

Trimet 

jodi lagged after the Maoist attack there in April 

2009, when several contractors and their workers 

left the place. 

Commissioning of the additional alumina 

capacity completes Nalco’s second phase of 

brownfield expansion, which also included an 

expansion of aluminium smelting capacity to 

460,000 tpy, from 345,000 tpy, an increase 

of bauxite mining capacity to 6.3m tpy, from 

4.8m tpy, and an increase in power generation 

capacity from 960 to 1,200 MW. Nalco 

is working on a debottlenecking project to 

increase primary aluminium production from 

existing smelters by a further 110,000 tpy in 

the next five years. 

� 

Secondary smelting and recycling 

Aleris files IPO registration 

Aleris Corp. has filed a registration statement 

on Form S-1 with the US Securities and 

Exchange Commission in connection with a 

proposed initial public offering of its common 

stock. Aleris Corp. changed its name from 

Aleris Holding Co. prior to the filing of the 

registration statement. The number of shares 

of common stock to be offered and the price 

range for the offering have not yet been determined. 

The shares of common stock to be 

sold in this offering (including the shares of 

common stock that may be sold to satisfy the 

underwriters’ over-allotment option) will be 

sold by Aleris Corp. and certain of its stockholders. 

Novelis launches ambitious plan 

to increase the use of recycled metal 

Novelis has announced a company-wide commitment 

to significantly reduce its carbon 

footprint as well as those of its customers. The 

commitment calls for an intensified focus on 

expanding the use of recycled materials, increasing 

post-consumer recycling of aluminium 

products and accelerating the development of 

new, high-recycled content alloys. Thus, Nov- 

elis will increase the 

amount of recycled 

metal it uses in its 

rolling operations 

to 80% by 2020. 

This corresponds 

to CO 2 emission 

savings of 10 million 

tpy. Recycled 

metal currently accounts 

for 34% of 

all material used by 

Novelis. 

With close to 

40bn remelted cans 

a year the world 

leader in the recycling 

of aluminium beverage cans, Novelis is 

planning major expansions of its recycling and 

remelting capacity around the globe. Early in 

February, the company announced the investment 

of USD18m for the construction of a new 

recycling centre at Aluminium Norf in Germany: 

the new multi-chamber melting furnace 

will recycle 50,000 tpy of aluminium scrap. 

In addition, Novelis will expand buyback 

opportunities to customers for the aluminium 

scrap they generate in their processes, including 

the collaboration with stakeholders to 

expand existing recycling programmes and 

educating consumers in the value of recycling 

to their communities and the world at large. 

Furthermore, Novelis is accelerating its R&D 

of new products for sustainable applications 

while also stepping up partnership activities 

with its customers targeting the next generation 

of aluminium alloys that enable increased 

use of post-consumer recycled metal. Through 

close collaboration during the design and development 

stages of its customers’ products, 

Novelis will leverage its leading position in developing 

innovative alloys that meet the combined 

performance and sustainability needs of 

its customers. 

As part of its sustainability commitment, 

the company will release its first public sustainability 

report in July this year. The sus- 


EAFA 

tainability commitment is being led by John 

Gardner, who was appointed vice president 

and chief sustainability officer early this year. 

General Aluminum 

closing Georgia-based die caster 

General Aluminum Manufacturing Co. (Gamco) 

will shut its die-casting plant in Rome, 

Georgia, just five months after acquiring the 

Aluminium semis 

Siemens offers alu foil 

rolling mills for small lot sizes 

Siemens VAI has developed a range of aluminium 

foil rolling mills with production capacity 

of up to 20,000 tpy. Thus, even small lot sizes 

can be rolled flexibly and with a fast return 

on investment. The rolling mill’s concept attaches 

particular importance to reduce construction 

and commissioning time, as well as 

The Author 

The author, Dipl.-Ing. R. P. Pawlek, is founder 

of TS+C, Technical Info Services and Consulting, 

Sierre (Switzerland), an established service 

for the primary aluminium industry. He is also 

the publisher of the standard works Alumina 

Refineries and Producers of the World and 

Primary Aluminium Smelters and Producers of 

the World. These reference works are continually 

updated and contain useful technical and 

economic information on all alumina refineries 

and primary aluminium smelters of the world. 

They are available as loose-leaf files and/or 

CD-ROMs from the Alu Media GmbH in Düsseldorf, 

Germany. 

facility. The closure of Rome Die Casting LLC 

could be permanent. The aluminium die caster 

will lay off all 67 workers at the plant and idle 

it by the end of April. The plant’s shutdown 

was not a sign of the health of the general 

die-casting sector but may be linked to issues 

specific to the plant. Some equipment needed 

upgrading at a great cost. The Rome facility 

uses high-pressure die casting to produce cast 

and machined transmission and steering components. 

� 

easy operation and 

maintenance. The 

Siroll aluminum 

foil rolling mills are 

available in roughing, 

intermediate 

and finishing mill 

configurations. All 

the foil rolling mills 

are equipped with 

Siemens automation 

systems including 

TCS (Technical 

Control System) for 

flatness and thickness 

control. 

A Siroll alu foil rolling line is designed to 

take a coil of AA 1000, AA 3000 or AA 8000 

series material of between 0.1 and 0.6 mm 

thick, 1,000 to 1,870 mm in width, weighing 

up to 16 tonnes and produce foil thicknesses 

of 2 x 6 microns at production speeds up to 

1,500 m/min. Flexible rolling programmes enable 

a swift response to changing market requirements, 

even with small lot sizes. 

Siemens supplies and commissions all of the 

mechanical and electrical equipment, fluids 

systems and process automation. User-friendly 

control and monitoring equipment includes 

diagnostic and alerting functions to ensure efficient 

and reliable operation. Product quality 

is assured by a series of linked measurement 

systems and actuators including systems for 

monitoring strip tension and rolling speed, an 

X-ray unit for determining strip thickness and 

Shapetech Flatness Air Bearing Shapemeter 

roll (ABS) and Shapetech ISV spray bars. 

To ensure the high quality, and to accelerate 

construction and commissioning, core 

components of the aluminum rolling mill are 

manufactured, pre-assembled and tested at 

regional Siemens locations according to the 

company’s rigorous in-house quality control 

standards. Siemens also provides training for 


the operator’s personnel and offers extensive 

after sales support by specialists at branch offices 

in the customer’s proximity. 

Hydro’s North Liberty plant 

to boost output and shape size 

Norsk Hydro ASA’s aluminium extrusion facility 

in North Liberty, Indiana, will boost its 

output by some 2,700 to 3,630 tpy – about 

30% – following a multimillion-dollar equipment 

upgrade. The first stage of the investment, 

which focussed on the three-press 

plant’s quenching system, cost some USD1.3m 

and was complete in March. The second phase, 

also costing around USD1.3m, will look at the 

plant’s stretcher and handling systems, and 

should be complete by the end of 2011. 

The investment will allow the North Liberty 

plant to produce heavier shapes for use 

in the transportation market. The plant, which 

includes two 7-inch presses and one 10-inch 

press, already supplies many of the more traditional 

transportation and recreational vehicle 

sectors, as well as some construction and consumer 

durable markets. 

Alcoa introduces architectural 

panel that cleans itself 

Alcoa Architectural Products has developed a 

proprietary process that leverages ‘Hydrotect’ 

technology from Japanese manufacturer Toto 

to apply a titanium dioxide coating, called Eco- 

Clean, to the pre-painted aluminium surface 

of Reynobond. The result is the world’s first 

coil-coated aluminium architectural panel that 

helps clean itself and the air around it. 

As a photocatalyst, titanium dioxide interacts 

with sunlight to break down organic matter 

both on and floating around the surface of 

the building panels, leaving the organic matter 

sitting on the surface of the Reynobond panel, 

ready to be washed away. When it rains, water 

does not bead on the surface. Instead, it collapses 

and runs evenly off the building, taking 

most of the broken down pollutants with it. 

That means lower maintenance costs for owners 

and a consistently cleaner image for the 

building over time. 

Reynobond with EcoClean actively works 

to remove pollutants by using sunlight, water 

vapour and oxygen in the air to clean the air 

itself. The company says 1,000 sqm of Reynobond 

with EcoClean on a building can have 

almost enough cleansing power to offset the 

smog created by the pollution output of four 

cars every day. 



Rexam to build new Brazilian can plant 

Global packaging company Rexam Plc will 

build a new aluminium can production plant 

in Brazil as it looks to capture growth in the 

booming consumer market. The plant, to be 

located in Northern Brazil near Belém, is due 

to come online in mid-2012. The plant will 

have an capacity of 1.2bn cans a year, increasing 

Rexam’s Brazilian capacity to about 14bn 

cans a year by the end of 2012. 

Can sheet for the plant will be supplied by 

aluminium rolled products company Novelis 

Inc. In May 2010, Novelis’ Brazilian subsidiary 

signed a multi-year can sheet supply contract 

to be the sole supplier of can body sheet for 

Rexam’s existing Brazilian facilities, as well as 

for its plant in Argentina. Novelis is also the 

main supplier of aluminium sheet for can ends 

at Rexam’s Brazil plants. 

Sun Capital purchases 

aluminium fabricator UGC 

Private investment firm Sun Capital Partners 

Inc. has expanded its portfolio of downstream 

metal-related assets with the purchase of architectural 

glass and aluminium products company 

United Glass Corp. (UGC). Louisville/ 

Kentucky-based UGC, which operates four 

manufacturing facilities in the eastern United 

States, is not Sun Capital’s first venture into 

the aluminium market. The Boca Raton/Florida-based 

investment firm bought Tamarac, 

Florida-based aluminium product fabricator 

and distributor Arch Aluminum & Glass LLC 

in January 2010, just months after Arch filed 

a voluntary Chapter 11 petition. In April of 

2010, Sun Capital also purchased former Rio 

Tinto Plc unit Alcan Beauty Packaging, which 

operates 26 plants across 12 countries. The 

unit has since been rebranded as Albea Inc. 

Florida aluminium extruder 

files for Chapter 11 protection 

Aluminium extruder Florida Extruders International 

(FEI) Inc. filed for Chapter 11 bankruptcy 

protection, citing an inability to pay its 

suppliers due to weakness in its customer base. 

The voluntary bankruptcy petition cited assets 

and liabilities of between USD10m and US- 

D50m and between 200 and 999 creditors. In 

an effort to meet its obligations, the company 

will file a liquidation plan to sell most or all of 

its assets in an auction with the help of Wells 

Fargo & Co., its largest secured creditor. 

FEI’s assets include three extrusion presses 

with a capacity of about 22,000 tpy, a recycling 

foundry and a powder coat finishing line. The 

company also bought a fourth extrusion press 

with 40% more capacity than the other three 

presses combined, but the installation could 

not be completed due to lack of funding. � 

Suppliers 

Alcan Iceland orders billet 

homogenising equipment 

Aluminum producer Alcan Iceland has placed 

an order with Austrian Hertwich Engineering 

for the supply of billet homogenising equipment. 

This order is part of Alcan Iceland’s 

smelter expansion project, Isal Production 

Upgrade (IPU) in Straumsvik. Production 

capacity will total 230,000 tpy of billets in 

diameters ranging from 178 mm to 254 mm. 

This will strengthen Alcan Iceland’s market 

position as supplier of high-quality billets in 

Northern Europe. The order comprises three 

ultrasonic inspection stations, three electrically 

heated continuous homogenising and cooling 

facilities as well as two packaging stations. 

Also the automation of the entire installation 

is part of Hertwich’s supply. The first installation 

stage is scheduled to be completed in 

2012, the second one in 2014. 

Buss AG delivers anode paste 

compounding lines to China 

In January 2011 China ordered two anode 

paste compounding lines from the Swiss com- 

Buss AG delivers two such kneader lines to China, each about 16 m long 

pany Buss AG, Pratteln. These lines process 

petroleum coke and pitch into high-grade anode 

paste for making electrolysis anodes used 

in the aluminium industry. Each line, both of 

which will be installed in South China, has a 

capacity of 40 t/h. Delivery including preheaters 

is scheduled for the end of this year, and 

production start-up for early 2012. This order 

further strengthens the market positioning of 

Buss AG as provider to the aluminium industry 

in China, where more then ten such compounding 

lines are already operating. 

Samsung Engineering awarded 

rolling mill plant contract 

Samsung Engineering has been awarded a 

USD590m contract from Ma’aden/Alcoa for 

their rolling mill plant project, located in Ras 

az Zawr, Saudi Arabia. With a planned capacity 

of 740,000 tpy of aluminium ingot, slab 

and billet and 380,000 tpy of aluminium sheet, 

Samsung will handle the EPC on a lump-sum 

turn-key basis with a completion date set for 

July 2013. 

In the contract is a novation portion of up to 

USD350m for additional materials and equipment. 

Furthermore, Samsung was formally selected 

for the casthouse portion in the smelter 

and also a port and silo facility of the aluminium 

complex after receiving a notice of award 

in March. In total, USD1.2bn of new orders 

for this aluminium complex has been awarded 

to Samsung. This project involves know-how 

from Samsung’s Industrial & Infrastructure divisions. 

This new order follows the mechanical 

completion of the ammonia plant contract with 

Ma’aden, which was awarded in 2007. � 


Buss AG

Abbildungen: IUL 

Um der globalen Erderwärmung entgegenzuwirken, 

besteht ein vorrangiges Ziel 

aktueller und zukünftiger Forschungsarbeiten 

in der Reduktion von CO 2-Emissionen 

sowohl im Bereich der Automobil- 

und Luftfahrtindustrie als auch bei 

energie- und ressourcenintensiven Fertigungsprozessen 

in der industriellen Herstellung 

metallischer Produkte. Um den 

Energieverbrauch von Verkehrsmitteln 

zu senken, ist der Einsatz und die Weiterentwicklung 

von Leichtbaustrukturen 

und leichteren innovativen Antrieben 

unumgänglich. Bezüglich des Energieverbrauches 

in den einzelnen Herstellungsstufen 

ist die urformtechnische 

Bereitstellung des Ausgangsmaterials 

wesentlich energieintensiver als die Zerspanungs- 

und Umformprozesse. Die direkte 

Verwertung von Aluminiumspänen 

für die Fertigung von Strangpressprofilen 

bietet eine ressourcenschonende Alternative 

zu diesen konventionellen energieintensiven 

Urformprozessen. Die aktuellen 

Forschungsarbeiten und Ergebnisse dieses 

innovativen Verfahrens werden im Folgenden 

vorgestellt. 

Stand der Technik 

Die Wiederverwertung von Aluminiumspänen 

durch Strangpressen wurde bereits 1945 

RESEARCH 

Strangpressen von Profilen aus Aluminiumspänen 

V. Güley, N. Ben Khalifa, A. E. Tekkaya, IUL, TU Dortmund 

Abb. 1: Struktur des Forschungsprojektes „Umformtechnische Wiederverwertung von Aluminiumspänen“ 

in den USA von Stern patentiert [1]. Er hat die 

von ihm entwickelte Anlage mit einem Drehofen 

aufgerüstet und das Konzept des kontinuierlichen 

Strangpressens von Spänen vorgestellt 

[2]. In [3] griffen Sharma und Nakagawa 

das Thema „Schmieden von pulverisierten 

Messingspänen“ auf. Takahashi [4] setzte sich 

mit dem Problem von Lufteinschlüssen auseinander 

und führte Strangpressversuche im 

Vakuum durch. 

Gronostajski et al. haben den Ansatz von 

[5-7] für die Herstellung unterschiedlicher 

Aluminium-Basis-Verbundwerkstoffe weiter 

untersucht. In [8] werden Untersuchungen 

von Allwood et al. dargestellt, die sich mit 

dem Kaltverschweißen von Aluminiumspänen 

beschäftigen. Peng et al. [9] untersuchten 

die mechanischen Eigenschaften einer Mg- 

Legierung, die durch „Continuous Cyclic 

Pressing“ (CCP) wiederverwertet wurden. 

Hier wurden 30-mm-Durchmesser-Blöcke zu 

20-mm-Durchmesser-Stangen verpresst und 

wieder auf 30 mm aufgestaucht. Dieser Vorgang 

wurde 2- bis 6-mal wiederholt und mit 

herkömmlichen Profilen verglichen. In weiterführenden 

Untersuchungen zeigten Peng et al. 

[10] den Einfluss der Spangröße im CCP-Verfahren 

auf. In [11] sind Aluminiumdrähte aus 

Spänen der Legierungen AA2050 und AA2195 

durch integriertes Reibrührschweißen und indirektes 

Strangpressen hergestellt worden. 

Abhängig von Kraft und Drehgeschwindigkeit 

war es möglich, Drähte mit unterschiedlichen 

Eigenschaften herzustellen. Hierbei wurde 

gezeigt, dass die Drähte nach einer Wärmebehandlung 

fehlerfreie Gefügezustände aufweisen. 

In [12] wurden AZ91-Magnesiumlegierungsspäne 

zuerst bei Raumtemperatur 

kalt- und im Anschluss bei 400 °C warmverdichtet. 

Die Blöcke konnten bei 350 °C mit 

einem Pressverhältnis von 12:1 stranggepresst 

werden. Für die Verfeinerung der Körner 

kam das ECAP-Verfahren („Equal Channel 

Angular Pressing“) bei 300 °C / 350 °C 

zur Anwendung. Nach dem ECAP konnten 

Abb. 2: Flachwerkzeug und Kammerwerkzeug für das Strangpressen von einem Rechteckprofil der Maße 

5 x 20 mm 


RESEARCH 

Abb. 3: Zugversuchsergebnisse beim Spänestrangpressen mit Flach- und Kammerwerkzeugen 

vergleichbare Eigenschaften im Vergleich zu 

konventionell hergestellten Profilen aus gegossenen 

Blöcken erreicht werden. 

Strangpressen von Profilen 

aus Aluminiumspänen 

Strangpressen von Profilen aus Aluminiumspänen 

wird der konventionellen Verarbeitung 

durch Einschmelzen, Stranggießen und 

Strangpressen gegenübergestellt und daraus 

resultierend ein bedeutendes Potenzial zur 

Verkürzung der Prozesskette gesehen. Dieses 

neue innovative Verfahren wurde gemäß dem 

in Abb. 1 dargestellten Ablauf erforscht. 

Abb. 4: Vergleichsumformgrade und -spannungen beim Spänestrangpressen mit 

Flach- und Kammerwerkzeugen 

Zur umformtechnischen Wiederverwertung 

von Aluminiumspänen durch das Strangpressen 

werden die Späne zunächst gereinigt, getrocknet 

und dann zu zylindrischen Blöcken 

in einer Hülse kompaktiert, schließlich erhitzt 

und zu Profilen verpresst. Dazu sind sowohl 

die aus Spänen erzeugten Blöcke als auch die 

stranggegossenen Aluminiumblöcke vor dem 

Strangpressen zunächst auf eine Temperatur 

von 450 bis 550 °C vorzuwärmen. Diese vorgeheizten 

Blöcke werden in der Strangpresse 

bei einer Werkzeugtemperatur von 450 °C 

verpresst. 

In den Untersuchungen konnte gezeigt 

werden, dass grundlegende Prozessrandbedingungen 

wie 

der Werkstofffluss, 

das Pressverhältnis 

und 

die Temperaturen 

die Eigenschaften 

des re- 

sultierenden 

Profils definieren. 

Um den 

Einfluss und 

die Wechselwirkungen 

der 

Bedingungen, 

unter denen 

das Verschweißen 

der Späne 

stattfindet, so- 

wohl auf den 

Strangpresspro- 

zess als auch auf die Profileigenschaften zu 

untersuchen, wurden die Einflüsse des Werkstoffflusses, 

des Umformgrads bzw. Pressverhältnisses, 

der Profilgeschwindigkeit und der 

Temperatur analysiert und im Folgenden vorgestellt. 

Einfluss des Werkstoffflusses 

Der Einfluss des Werkstoffflusses auf die 

Eigenschaften der erzeugten Profile wurde 

anhand von zwei Werkzeugen zur Fertigung 

eines Flachprofils mit dem Querschnitt 20 x 

5 mm untersucht. Die Werkzeuge sind zum 

einen als Flachwerkzeug, zum anderen als 

Kammerwerkzeug mit Schweißkammer ausgeführt. 

Konventionell werden Kammerwerkzeuge 

(Abb. 2) zur Fertigung von Hohl- und 

Mehrkammerprofilen genutzt. 

Bei einer Werkzeug- und Rezipiententemperatur 

von 450 °C wurden die auf 500 °C 

vorgeheizten Späneblöcke mit einer Profilgeschwindigkeit 

von 34 mm/s zu Profilen verpresst. 

Die Legierung EN AW-6060 ist aushärtbar, 

daher ist es wichtig, auch den Zustand 

nach der Wärmebehandlung zu untersuchen. 

Die stranggepressten Profile wurden bei einer 

Temperatur von 530 °C für drei Stunden lösungsgeglüht, 

in einem Wasserbad auf Raumtemperatur 

abgeschreckt und anschließend bei 

175 °C für acht Stunden warmausgelagert (T6 

Wärmebehandlungszustand). 

Bei diesen Arbeiten dient der unkonventionelle 

Einsatz des Kammerwerkzeugs zur 

Erhöhung des Pressdrucks und des Durchknetungsgrads 

durch Änderung des Werkstoffflusses 

gegenüber einer Flachmatrize. 

Als Erklärung für die positive Wirkung des 

Einsatzes eines Kammerwerkzeuges können 

die dargestellten Zugversuchsergebnisse herangezogen 

werden (Abb. 3). Bei gleicher Zugfestigkeit 

weisen die mit dem Kammerwerkzeug 

gepressten Profile eine Bruchdehnung 

von 27% gegenüber 17% bei Profilen, die mit 

Flachwerkzeugen gefertigt wurden, und damit 

eine deutlich höhere Duktilität auf. Hierbei 

zeichnet sich ab, dass beim Spänestrangpressen 

über die Änderung des Werkstoffflusses 

ein erheblicher Einfluss auf das Gefüge, den 

Gefügeverbund und damit auch auf die Profileigenschaften 

genommen werden kann [13]. 

Um diese Phänomene zu analysieren, 

wurde die Umformhistorie mittels FEM mit 

dem Programm DEFORM 3D simuliert. Abb. 

4 stellt die Vergleichsumformgrade und die 

Vergleichsspannungen für die Flachmatrize 

und das Kammerwerkzeug als ein Ergebnis 

der durchgeführten FEM-Simulationen dar. 

Durch den Einsatz des Kammerwerkzeugs 

wird im Vergleich zum Flachwerkzeug eine 


viermal höhere Vergleichsspannung in der 

Verschweißungszone erreicht. Dies resultiert 

in einem deutlich höheren Umformgrad im 

Profil, wodurch eine stärkere Verschweißung 

der Späne zu erwarten ist. Die höhere Duktilität 

der Profile kann durch den großen Umformgrad 

erklärt werden. Dies ist wiederum 

auf den Einsatz eines Kammerwerkzeuges 

zurückzuführen. 

Die Mikrostruktur der Profile vor und nach 

der T6-Wärmebehandlung wurde anhand 

von Gefügeschliffen bewertet. Vor der Wärmebehandlung 

ergab die durchschnittliche 

Korngröße der Profile, stranggepresst mit 

dem Flachwerkzeug, einen Wert von 120 μm, 

während die für das Kammerwerkzeug 240 

μm betrug. Bei den mit dem Flachwerkzeug 

stranggepressten Profilen behinderten die 

Oxidschichten zwischen den Oberflächen der 

Spanverschweißungen das Kornwachstum. 

Abb. 5: Ergebnisse der Zugversuche von Profilen, gepresst mit unterschiedlichen Pressverhältnissen bei 

einer Profilgeschwindigkeit von 20 mm/s 

RESEARCH 

Im Gegensatz dazu trennen sich die Oxidschichten 

bei den Profilen, die mit Kammerwerkzeug 

stranggepresst wurden, voneinander, 

verteilen sich im Gefüge und behindern 

somit nicht das Kornwachstum [14, 15]. Dies 

führt zusammen mit der höheren Reibung im 

Kammerwerkzeug und somit einer höheren 

Profilaustrittstemperatur zu einer grobkörnigeren 

Struktur und zu einer höheren Duktilität 

der Profile. 

Einfluss des Umformgrads 

bzw. Pressverhältnisses 

Anhand von kompaktierten Blöcken der 

EN AW-6060-Späne wurde der Einfluss des 

Umformgrads bzw. des Pressverhältnisses, 

der Profilgeschwindigkeit und der Blocktemperatur 

auf das Prozessverhalten und die 

Produkteigenschaften untersucht, und die 

Späne wurden bei drei verschiedenen Blocktemperaturen 

und drei unterschiedlichen 

Profilgeschwindigkeiten zu Rechteckprofilen 

verpresst. Um den Einfluss des Umformpfads 

zu untersuchen, kamen drei Flachwerkzeuge 

mit Pressverhältnissen von 10:1 (34 x 10 mm 

Rechteckprofil), 34:1 (20 x 5 mm Rechteckprofil) 

und 68:1 (12,5 x 4 mm Rechteckprofil) 

zum Einsatz. Die mit einer Profilgeschwindigkeit 

von 20 mm/s und unterschiedlichen 

Pressverhältnissen erzeugten Profile wurden 

durch Zugversuche untersucht (Abb. 5). Es ist 

zu erkennen, dass die Profile mit dem Pressverhältnis 

68:1 eine deutlich höhere Festigkeit 

(21%) und Duktilität (15%) aufweisen 

als die mit einem Pressverhältnis von 34:1 

gefertigten. Durch Erhöhung des Pressverhältnisses 

werden der Druck in der Schweißkammer 

und somit auch die Temperatur erhöht, 

sodass die Späne besser verschweißen 

können. Die Profile aus gegossenen Blöcken, 

stranggepresst bei verschiedenen Pressverhältnissen 

(PV= 68:1, 34:1 und 10:1), weisen 

das gleiche mechanische Verhalten auf. 

Das Verhalten der aus Spänen stranggepressten 

Profile nähert sich dem von konventionellen 

Profilen an, je höher das Pressverhältnis 

gewählt wird. Bei einem Pressverhältnis 

von 10:1 konnte kein ausreichender Druck 

auf die Späne erzeugt werden, sodass keine 

Verschweißung der Späne zu erzielen war. 

Abhängig von den Prozessrandbedingungen 

treten verschiedene Fehler bei diesen Profilen 

auf. Die Ergebnisse zeigen, dass je höher 

das Pressverhältnis ist, desto höher die Festigkeit 

und die Duktilität der Profile werden. Bei 

geringeren Pressverhältnissen besteht die Gefahr, 

dass keine ausreichende Verschweißung 

der Späne stattfindet und die Profile große 

Gestaltungsfehler aufweisen. 

Abb. 6: Zugversuchsergebnisse bei Profilgeschwindigkeiten von 10, 20 und 30 mm/s � 


RESEARCH 

Abb. 7: Zugversuchsergebnisse der 30 x 30-mm-Vierkantprofile, stranggepresst bei unterschiedlichen 

Blocktemperaturen 

Einfluss der Profilgeschwindigkeit 

und der Temperatur 

Aufgrund der engen Verknüpfung zwischen 

der Profilgeschwindigkeit und der Werkstück- 

bzw. der Werkzeugtemperatur (Beispiel 

Heißrisse) wurden diese Parameter gemeinsam, 

wiederum durch die Auswertung 

von Zugversuchen, analysiert. Bei einer niedrigeren 

Blockeinsatztemperatur von 450 °C 

nehmen „Zugfestigkeit“ (R m ) und „Dehnung 

bei Höchstkraft“ (A gt ) mit zunehmender 

Pressgeschwindigkeit ab (Abb. 6). Das heißt, 

dass bei niedrigeren Blocktemperaturen die 

Verschweißung besser und die Duktilität 

höher wird, je kleiner die Profilgeschwindigkeit 

ist. Aufgrund der erhöhten Viskosität 

der Legierung EN AW-6060 bei 450 °C ist 

der Werkstofffluss ungünstiger im Vergleich 

zu einer Temperatur von 550 °C. Nach dem 

Anstauchen im Rezipienten ist das Porenvolumen 

zwischen den Spänen stark reduziert. 

Der durch die Matrize fließende Werkstoff 

kann als Aluminium mit geringer Porosität 

betrachtet werden, sodass bei kleineren Profilgeschwindigkeiten 

der Werkstoff, der unter 

Druck durch die Matrize fließt, ausreichend 

Zeit findet, in diese Poren zu diffundieren. 

Daraus resultiert eine bessere Verschweißung 

der Späne. Aufgrund der niedrigen Viskosität 

des Aluminiums bei 550 °C findet der Diffusionsvorgang 

sowohl bei 10 mm/s Profilgeschwindigkeit 

als auch bei 30 mm/s gleichermaßen 

statt. Bei einer Blocktemperatur von 

350 °C zeichnet sich an der Profiloberfläche 

eine unzureichende Verschweißung der Späne 

ab. Im Zugversuch wird dies durch eine sich 

einstellende Delaminierung der Zugversuchsprobe 

bestätigt. Pressungen auf diesem niedrigen 

Temperaturniveau wurden daher nicht 

weiter verfolgt. 

Neben dem Flachprofil (Pressverhältnis 

von 34:1) wurde auch beim Pressen eines 

Hohlprofils mit quadratischem Querschnitt 

von 30 x 30 mm und einer Wanddicke von 

1,8 mm (Pressverhältnis von 17:1) der Einfluss 

der Blocktemperatur untersucht. Als Referenz 

wurden gegossene Blöcke mit 550 °C 

Einsatztemperatur eingesetzt. Die Ergebnisse 

der Zugversuche sind in Abb. 7 dargestellt. 

Die Profile aus Spänen erreichen bis zu 90% 

der Festigkeit von aus Gussmaterial gefertigten 

Profilen. Niedrigere Blocktemperaturen 

führen zu Reduktionen der Zugfestigkeit um 

bis zu 25% (40 MPa). Die Analyse dieser bei- 

den Profile zeigte, dass die Verschweißung der 

Späne bei höheren Blocktemperaturen besser 

ist, da das Aufbrechen der Oxidschichten bei 

hohen Temperaturen vereinfacht wird. 

Gefügeentwicklung 

beim Spänestrangpressen 

Abb. 8 stellt das Gefügebild der Rechteckhohlprofile 

im Längsschliff dar. In den Schichten 

zwischen den Spanverschweißungen können 

unterschiedliche Korngrößen bestimmt werden. 

Diese Beobachtung bestätigt, dass das 

Kornwachstum aufgrund der Oxidschichten 

zwischen den Oberflächen der Spanverschweißungen 

behindert wird [Hum04 und 

Gee05]. Somit stellt sich das Kornwachstum 

innerhalb einer solchen Schicht ein. Wenn 

diese Oxidschichten unter hoher Temperatur 

und hohem Druck aufbrechen, können die 

Körner über die ursprünglichen Spangrenzen 

hinaus wachsen und somit wird eine bessere 

Verschweißung der Späne ermöglicht. 

Die Gefügeentwicklung während des Spänestrangpressens 

wurde anhand von Gefügeschliffen 

bewertet. Hierzu wurden die Profile 

metallografisch präpariert und elektrolytisch 

mit einer Barkerätzung angeätzt. Die Gefügeentwicklung 

wurde anhand von vier Aufnahmen, 

gekennzeichnet von A bis D, analysiert 

(Abb. 9). Aufnahme A zeigt die kompaktierten 

und plastisch verformten Späne, ohne dass 

eine Verschweißung zwischen diesen stattgefunden 

hat. In einer vergrößerten Aufnahme 

sind die Grenzflächen zwischen den Spänen 

deutlich erkennbar (Aufnahme D). Die Späne 

besitzen ein feinkörniges Gefüge mit einer 

mittleren Korngröße von 50 μm. In der Scherzone 

(Aufnahme B) kann die Rekristallisation 

der Körner bis zu den Oxidschichten beobachtet 

werden. Während der Pressung durch 

die Matrize brechen die Oxidschichten unter 

hohem Druck und hoher Temperatur auf und 

es kommt zum Kontakt zwischen zwei Aluminiumgrenzflächen. 

Während der dynamischen 

Rekristallisation, die teilweise von im Gefüge 

verteilten Aluminiumoxidpartikeln beein- 

Abb. 8: Gefügebilder der Rechteckhohlprofile, stranggepresst aus EN AW-6060-Spänen in Längsschliff 


flusst wird, wird eine feinkörnige Mikrostruktur 

erreicht (Aufnahme C). Im stranggepressten 

Profil sind die Grenzflächen zwischen den 

Spanverschweißungen nicht mehr erkennbar. 

Die mittlere Korngröße der verpressten Profile 

beträgt etwa 100 μm. 

Zusammenfassung und Ausblick 

In den Untersuchungen konnte gezeigt werden, 

dass grundlegende Prozessrandbedingungen 

wie Werkstofffluss, Pressverhältnis 

und Blocktemperatur die mechanischen 

Eigenschaften des resultierenden Profils definieren. 

Bei höheren Pressverhältnissen und 

Blocktemperaturen war es möglich, eine bessere 

Verschweißung der Späne und dadurch 

höhere Werte für die Festigkeit und Duktilität 

der Aluminiumprofile zu erzielen. Durch eine 

Änderung des Werkstoffflusses, zum Beispiel 

mit dem unkonventionellen Einsatz eines 

Kammerwerkzeugs gegenüber einer Flachmatrize, 

konnte mit der Erhöhung des Pressdrucks 

und des Durchknetungsgrads eine 

größere Duktilität bei den erzeugten Profilen 

erreicht werden. Die Profilgeschwindigkeit 

zeigt hingegen nur in Abhängigkeit von der 

Blocktemperatur einen signifikanten Einfluss. 

Für die Herstellung der Aluminiumprofile 

können die Aluminiumspäne bzw. Schrott, 

Primäraluminium oder Sekundäraluminium 

eingesetzt werden. Der Energieverbrauch 

beim Strangpressen der Profile aus Aluminiumspänen 

beträgt im Durchschnitt nur 14% 

der Energie, die zur Erzeugung von Sekundäraluminiumblöcken 

erforderlich ist. Das bedeutet 

einen enormen Energiegewinn und die 

Schonung der wichtigen Ressourcen. Zusätzlich 

wird damit die Menge des CO 2 -Ausstoßes 

deutlich verringert, sodass dieses Verfahren 

zu den Maßnahmen gegen die globale Erwärmung 

gezählt werden kann. Die gewonnenen 

Erkenntnisse können für künftige weitere 

Forschungsarbeiten im Bereich der Wiederverwertung 

anderer Leichtbauwerkstoffe wie 

Magnesium, Titan usw. hilfreich sein. 

Basierend auf den gewonnenen Erkenntnissen 

ist es im Weiteren sinnvoll, die Zusammenhänge 

zwischen Prozessführung und 

Werkzeuggestaltung präzise herauszustellen, 

um eine ganzheitliche Prozessbeschreibung 

realisieren zu können. Hierzu ist zunächst 

eine sukzessive Steigerung des Komplexitätsgrades 

der Profile sinnvoll, um entsprechende 

Wirkzusammenhänge aufzuzeigen. Dies kann 

sowohl über die Ausweitung der Untersuchungen 

auf Mehrkammerhohlprofile als 

auch auf komplexere Vollprofile erfolgen. Da 

die Prozessparameter signifikant vom Legierungssystem 

beeinflusst werden, ist es darüber 

RESEARCH 

Abb. 9: Gefügeentwicklung während des Spänestrangpressens, Flachwerkzeug, 20 x 5 mm Rechteckprofil 

hinaus zielführend, das ermittelte Prozessfenster 

im Bereich der Aluminiumlegierungen 

auf Guss- sowie auf aushärtbare und nicht 

aushärtbare Knetlegierungen zu erweitern. 

Danksagung 

Diese Veröffentlichung basiert auf Forschungsarbeiten 

des DFG Projekts TE 508/12- 

1 BI 498/8-1 gemeinsam mit dem Institut für 

Spanende Fertigung der TU Dortmund, das 

von der Deutschen Forschungsgemeinschaft 

(DFG) gefördert wird. 

Literatur 

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[2] Stern, M.: Direct Extrusion Applied to Light Metal 

Scrap, The Iron Age, Band 28/6, 1951. 

[3] Sharma, C.; Nakagawa, T.: Recent Development 

in the Recycling of Machining Swarfs by Sintering 

and Powder Forging, Annals of the CIRP, 25/1, 1977. 

[4] Takahashi, T.: Development of scrap extrusion 

reformation and utilization process, Proc. 2. Internat. 

Aluminum Extrusion Technol. Seminar, Band 1, 

1977, S. 123-128. 

[5] Gronostajski, J. Z.; Marciniak, H.; Matuszak, A: 

Production of Composites on the base of AlCu4 

Alloy Chips, Journal of Materials Processing Technology 

60, 1996, S. 719-722. 

[6] Gronostajski, J. Z.; Kaczmar, J. W.; Marciniak, H.; 

Matuszak A.: Production of composites from Al and 

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Technology 77, 1998, S. 37-41. 

[7] Gronostajski, J. Z.; Marciniak, H.; Matuszak, A.; 

Samuel, M.: Aluminium-ferro-chromium composites 

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[8] Allwood, J. M.; Huang, Y.; Barlow, C. Y: Recycling 

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23–30. 

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Autoren 

MSc. Volkan Güley ist wissenschaftlicher Mitarbeiter 

am Institut für Umformtechnik und Leichtbau 

der TU Dortmund. Er beschäftigt sich mit dem 

Spänestrangpressen. 

Dipl.-Ing. Nooman Ben Khalifa ist Oberingenieur 

am Institut für Umformtechnik und Leichtbau der 

TU Dortmund. Er ist zuständig für Forschungsarbeiten 

am Institut. 

Prof. Dr.-Ing. A. Erman Tekkaya ist Leiter des Instituts 

für Umformtechnik und Leichtbau der TU 

Dortmund. 


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das Mittel gegen das Herausrutschen des Ausfachungselements 

enthält. Norsk Hydro ASA, 

0240 Oslo, NO. (E06B 3/62, EPA 2278109, EP- 

AT: 23.07.2010) 

Verfahren zur Herstellung eines beschichteten 

Aluminiumbandes, Aluminiumband und dessen 

Verwendung. Hydro Aluminium Deutschland 

GmbH, 53117 Bonn, DE. (B05D 7/14, PS 10 

2009 003 683, AT: 26.03.2009) 

Lötverfahren für Wärmetauscher und Solarkollektoren. 

Hydro Aluminium Deutschland GmbH, 

53117 Bonn, DE. (B23K 1/005, OS 10 2009 043 

985, AT: 11.09.2009) 

Einrichtung und Verfahren zur Sammlung der 

Abflüsse einer Elektrolysezelle. Aluminium Pechiney, 

Voreppe, FR. (C25C 3/22, EP 1 845 175, 

EP-AT: 11.04.2006) 

Vorrichtung zur mittigen Anordnung und lösbaren 

Festlegung einer Leiste in einer nach 

außen offenen Nut. WKW Erbslöh Automotive 

GmbH, 42349 Wuppertal, DE. (B62D 25/06, GM 

20 2007 016 803, AT: 01.12.2007) 

Wärmetauscher, insbesondere zur Anwendung 

bei Kühlmöbeln. Erbslöh Aluminium 

GmbH, 42553 Velbert, DE. (F28F 13/06, GM 20 

2010 014 956, AT: 30.10.2010) 

Holz-Aluminium-Fenster. Gutmann AG, 91781 

Weißenburg, DE. (E06B 3/263, PS 100 37 

667 u. PS 101 00 101, AT: 02.08.2000 u. AT: 

03.01.2001) 

Kunststofffenster mit einer Metallfensterbank. 

Gutmann AG, 91781 Weißenburg, DE. (E06B 

1/70, PS 199 12 083, AT: 18.03.1999) 

Wärmegedämmte Schutzschiene für Fenster 

oder Türen. Gutmann AG, 91781 Weißenburg, 

DE. (E06B 1/34, PS 100 37 880, AT: 

03.08.2000) 

Zarge für ein Fenster oder eine Tür in wärmegedämmter 

Ausführung. Gutmann AG, 91781 

Weißenburg, DE. (E06B 1/32, PS 100 40 497, AT: 

18.08.2000) 

Kolben für einen Verbrennungsmotor. Mahle 

International GmbH, 70376 Stuttgart, DE. (F02F 

3/22, OS 10 2009 039 217, AT: 28.08.2009) 

Verfahren zur Herstellung eines Aluminiumkolbens 

für einen Verbrennungsmotor. Mahle 

International GmbH, 70376 Stuttgart, DE. (B23P 

15/10, OS 10 2009 040 120, AT: 04.09.2009) 

Mehrteiliger, gekühlter Kolben für einen Verbrennungsmotor. 

Mahle International GmbH, 

70376 Stuttgart, DE. (F02F 3/22, PS 50 2005 009 

010, EP 1828587, EP-AT: 28.11.2005) 

Homogenisierung und Wärmebehandlung von 

Gussmetallen. Novelis Inc., Toronto, ON M8Z 

1J5, CA. (B22D 11/00, EPA 2283949, EP-AT: 

27.10.2006) 

Verfahren zum Gießen eines Verbundbarrens. 

Novelis Inc., Toronto, ON M8Z 1J5, CA. 

(B22D 11/00, EPA 2279813 u. EP 2279814 u. EP 

2279815, EP-AT: 23.06.2004) 

Aluminiumbandmaterial für lithographische 

Druckplatten. Fujifilm Corp., Tokyo 106-8620, 

JP; Sumitomo Light Metal Industries, Ltd., Minato-ku 

Tokyo 105-8601, JP. (C22B 9/02, EPA 

2284288, EP-AT: 24.07.2010) 

Aluminiumlegierungsgussmaterial zur Wärmebehandlung 

mit ausgezeichneter Wärmeleitfähigkeit 

und Herstellungsverfahren dafür. 

Nippon Light Metal C. Ltd., Shinagawa-ku, Tokyo 

140-8628, JP. (C22C 21/02, EPA 2281909, EP- 

AT: 05.04.2005) 

Patentblatt April 2011 

Verfahren zum Erreichen verbesserter epitaxialer 

Qualität (Oberflächenstruktur und 

Defektdichte) auf freistehenden (Aluminium, 

Indium, Gallium) Nitrid((Al, In, Ga)N)-Substraten 

für optoelektronische und elektronische 

Vorrichtungen. Cree, Inc., Durham, NC 27703, 

US. (C30B 23/02, EPA 2290135 u. EP 2 290 136, 

EP-AT: 27.06.2001) 

Feinkristalline Al 2 O 3 -Keramik. CeramTec GmbH, 

73207 Plochingen, DE. (C04B 35/111, OS 10 

2005 059 099, AT: 08.12.2005) 

Al-Zn-Mg-Legierungsprodukt mit verringerter 

Quetschempfindlichkeit. Aleris Aluminum 

Koblenz GmbH, 56070 Koblenz, DE. (C22C 

21/10, EPA 2288738, WO 2009/156283, EP-AT: 

12.06.2009, WO-AT: 12.06.2009) 

Verwendung einer Al-Mn-Legierung für hochwarmfeste 

Erzeugnisse. TU Clausthal, 38678 

Clausthal-Zellerfeld, DE. (C22C 21/06, PS 10 

2007 023 323, AT: 16.05.2007) 

Al-Ni-Mn-Gusslegierung für Strukturkomponenten 

von Fahrzeugen sowie in der Luft- 

und Raumfahrt. Alcoa Inc., Pittsburgh, Pa., US. 

(C22C 21/06, GM 203 21 845, AT: 19.11.2003) 

Gegenüber Wasser reaktiver Al-Verbundwerkstoff, 

gegenüber Wasser reaktiver Al-Film, 

Verfahren zur Herstellung des Al-Films und 

Bauelement für Filmabscheidungskammer. Ulvac, 

Inc., Chigasaki-shiKanagawa 253-8543, JP. 

(C23C 4/06, EPA 2287354, WO 2009/133838, 

EP-A 27.04.2009, WO-AT: 27.04.2009) 

Elementstruktur mit einem Verdrahtungsmaterial 

aus Al-Ni-B-Legierung. Mitsui Mining & 

Smelting Co., Ltd., Tokio, JP. (C22C 21/00, EP 1 

878 809, WO 2006/117954, EP-AT: 30.03.2006, 

WO-AT: 30.03.2006) 

Verfahren zur Herstellung eines Katalysators 

und/oder Partikelabscheiders aus einem Legierungswerkstoff 

mit Aluminium- und Chromanteilen 

sowie dieser Legierungswerkstoff und 

dessen Verwendung. Oberland Mangold GmbH, 

82438 Eschenlohe, DE. (F01N 3/035, C22C 21/ 

00, EPA 2159388, EP-AT: 29.08.2008) 

Auf Aluminium basierendes Kornverfeinerungsmittel. 

Asturiana De Aleaciones, S.a., Asturias, 

ES; Banerji, Abinash, Berlin, DE. (C22C 

1/02, EPA 2295608, WO 2009/153369, EP-AT: 

10.06.2009, WO-AT: 10.06.2009) 

Verfahren zur Herstellung von gelöteten Aluminium-Wärmetauschern. 

Uop LLC, 25 East 

Algonquin Rd.P.O. Box 5017 Des Plaines, Illinois 

60017-5017, US. (F28F 3/02, EPA 2291598, 

WO 2010/005611, EP-AT: 13.04.2009, WO-AT: 

13.04.2009) 

Servierwagen aus einem lebensmittelfreundlichen 

Metall wie Aluminium, Edelstahl oder 

Ähnlichem. Köhler GmbH, 57562 Herdorf, 

DE. (A47B 31/00, PS 10 2009 034 199, AT: 

22.07.2009) 

ALUMINIUM veröffentlicht unter dieser Rubrik 

regelmäßig einen Überblick über wichtige, 

den Werkstoff Aluminium betreffende 

Patente. Die ausführlichen Patentblätter und 

auch weiterführende Informationen dazu 

stehen der Redaktion nicht zur Verfügung. 

Interessenten können diese beziehen oder 

einsehen bei der 

Mitteldeutschen Informations-, Patent-, 

Online-Service GmbH (mipo), 

Julius-Ebeling-Str. 6, 

D-06112 Halle an der Saale, 

Tel. 0345/29398-0 

Fax 0345/29398-40, 

www.mipo.de 

Die Gesellschaft bietet darüber hinaus weitere 

Patent-Dienstleistungen an. 


Gebäudeelement in brandgeschützter Ausführung. 

Norsk Hydro ASA, Oslo, NO. (E06B 3/263, 

EP 1 793 073, EP-AT: 16.11.2006) 

Im Wesentlichen chromfreies Verfahren zum 

Passivieren von metallischen Oberflächen aus 

Zn oder Zn-Legierungen, Al oder Al-Legierungen. 

BASF SE, 67063 Ludwigshafen, DE. (C23C 

22/53, PS 50 2004 011 004, EP 1678344, EP-AT: 

15.10.2004) 

Verwendung eines Fluoridflussmittels zur Kristallisation 

von Seltenerd-Aluminium-Granat 

aus einer Schmelze zur Herstellung optischer 

Elemente für die Mikrolithographie sowie 

von Szintillatoren. Schott AG, 55122 Mainz, 

DE. (C30B 29/28, OS 10 2009 043 002, AT: 

25.09.2009) 

Herstellung von Seltenerd-Aluminium- oder 

-Gallium-Granat-Kristallen aus einer fluoridhaltigen 

Schmelze sowie ihre Verwendung 

als optisches Element für die Mikrolithographie 

sowie als Szintillator. Schott AG, 55122 

Mainz, DE. (C30B 29/28, OS 10 2009 043 003, 

AT: 25.09.2009) 

Bilden von komplexen Formen in Aluminium- 

und Magnesiumlegierungswerkstücken. 

GM Global Technology Operations, Inc., Detroit, 

Mich., US. (B23P 7/00, OS 10 2010 035 136, AT: 

23.08.2010) 

Pyrogen hergestellte Aluminium-Silizium- 

Mischoxide, Dispersionen daraus hergestellt 

und dessen Verwendungen. Evonik Degussa 

GmbH, 45128 Essen, DE. (C01F 7/02, EP 1 277 

702, EP-AT: 11.04.2002) 

Ölkühler mit Aluminiumplatten. Delphi Technologies, 

Inc., Troy, Mich., US. (F28D 9/00, PS 602 

35 853, EP 1231447, EP-AT: 14.01.2002) 

Zusammensetzung, Lösung und Verfahren 

zur Oberflächenbehandlung von Aluminium 

und seinen Legierungen. Nippon Paint Co., 

Ltd., Osaka, JP. (C23C 22/36, PS 696 00 720, EP 

0774535, EP-AT: 13.11.1996) 

Verfahren zum Tempern einer Aluminiumlegierung. 

Standex International Corp., Salem, 

New Hampshire 03079, US. (C22F 1/04, EPA 

2294238, WO 2009/157975, EP-AT: 15.06.2009, 

WO-AT: 15.06.2009) 

Verfahren zur Herstellung von Formteilen aus 

Aluminiumlegierung vom Typ 2024. Pechiney 

Rhenalu, Paris, FR. (C22C 21/16, PS 600 20 188, 

EP 1045043, EP-AT: 10.04.2000) 

Produkte aus hochfester Aluminiumlegierung 

und Herstellungsverfahren dafür. Alcan Rhenalu, 

Paris, FR. (C22C 21/00, PS 60 2005 020 487, 

EP 1809779, EP-AT: 19.09.2005) 

Auftragsschweißverfahren eines Werkstücks 

in Aluminiumlegierung. SNECMA, Paris, FR. 

(B23K 26/34, PS 60 2008 000 913, EP 1961513, 

EP-AT: 15.02.2008) 

Direktstrangpressen von Formen mit L12- 

Aluminiumlegierungen. United Technologies 

Corp., Hartford, CT 06101, US. (C22C 1/04, 

EPA 2295609, EP-AT: 15.09.2010) 

Aluminiumlegierung für Metallschäume, ihre 

Verwendung und Verfahren zur Herstellung. 

Helmholtz-Zentrum Berlin für Materialien und 

Energie GmbH, 14109 Berlin, DE. (C22C 21/06, 

OS10 2008 027 798, AT: 11.06.2008) 

Verfahren und Vorrichtung zur Herstellung 

von Leichtmetall-Pellets. Druckguss Service 

Deutschland GmbH, 23568 Lübeck, DE. (B22D 

11/06, PS 199 56 479, AT: 24.11.1999) 

Legierung auf Mg-Basis. National Institute for 

Materials Science, Tsukuba-shi, Ibaraki 305- 

0047, JP. (C22C 23/04, EPA 2295613, WO 

2009/148093, EP-AT: 03.06.2009, WO-AT: 

03.06.2009) 

Beständiger Magnesium-Oxychlorid-Zement 

und Verfahren dafür. Promat Research and 

Technology Centre N.V., 2830 Tisselt, BE. (C04B 

28/32, EPA 2285750, WO 2009/141325, EP-AT: 

19.05.2009, WO-AT: 19.05.2009) 

Verfahren zur Herstellung von reinem, für 

eine Magnesium-Metallherstellung geeignetes 

Carnallit-NaCI-Kristallisat aus Carnallitsole. 

K-UTEC AG Salt Technologies, 99706 Sondershausen, 

DE. (C01F 5/30, PS 103 04 315, AT: 

04.02.2003) 

Mutterbefestigung mit einem Magnesiumplatinenteil 

oder Magnesium-Legierungsblechteil. 

TechMag AG, Baar, CH. (F16B 37/04, GM 202 

15 488, AT: 09.10.2002) 

Verfahren zum Fließpressen von Magnesium- 

Knetlegierungen und derart hergestellter Gegenstand. 

Neuman Aluminium Fliesspresswerk 

GmbH, Marktl, Lilienfeld, AT. (B21C 23/00, EP 

1 941 953, EP-AT: 09.10.2007) 

Oberflächenbehandlung zur Verbesserung 

der Korrosionsbeständigkeit von Magnesium. 

Alonim Holding Agricultural Cooperative Society 

Ltd., Kibbutz Alonim, IL. (C23C 22/34, PS 602 35 

927, EP 1736567, EP-AT: 25.06.2002) 

Resorbierbare Magnesiumlegierung. Synthes 

GmbH, 4436 Oberdorf, CH. (C22C 23/04, EPA 

2294236, WO 2009/148515, EP-AT: 21.05.2009, 

WO-AT: 21.05.2009) 

Selbst abgeschiedene Beschichtungen auf Magnesiumlegierungen. 

GM Global Technology 

Operations, Inc., Detroit, Mich., US. (C25D 11/30, 

OS 11 2009 001 005, WO-AT: 22.04.2009) 

Behälter mit abziehbarem Deckel mit Schutz 

vor unbefugtem Öffnen. Alcan Technology & 

Management Ltd., 8212 Neuhausen am Rheinfall, 

CH. (B65D 77/20, EPA 2159164, EP-AT: 

29.08.2008) 

Käseproduktverpackung, verpacktes Käseprodukt, 

Verwendung sowie Verfahren zum Herstellen 

einer Käseproduktverpackung. Alcan 

Technology & Management Ltd., Neuhausen am 

Rheinfall, CH. (B65D 65/40, OS 10 2009 050 898, 

AT: 27.10.2009) 

PATENTE 

Verfahren und Vorrichtung zum Reibrührschweißen 

von mindestens zwei Bauteilen 

aus artverschiedenen Werkstoffen mit einem 

verschiebbaren Stift und durch die Bauteile 

fließendem elektrischen Strom. Hydro Aluminium 

Deutschland GmbH, 51149 Köln, DE. (B23K 

20/12, EP 1 716 959, EP-AT: 27.04.2006) 

Verbundgusskolben und Verfahren zu seiner 

Herstellung. Alcan Deutschland GmbH, 

37075 Göttingen, DE; Volkswagen AG, 38440 

Wolfsburg, DE. (F16J 1/00, PS 198 13 430, AT: 

27.03.1998) 

Verbundprofil mit einem Tragkörper aus 

Leichtmetallwerkstoff sowie einem Profilband 

und Verfahren zum Herstellen des Verbundprofils. 

Alcan Technology & Management AG, 

Neuhausen am Rheinfall, CH. (F16S 1/02, GM 20 

2005 006 592, AT: 31.01.2005) 

Verfahren zur Vorbereitung eines Filters 

für Metallschmelze. Alcan International Ltd., 

Montreal, Quebec, CA. (B22D 43/00, PS 60 2005 

020 435, EP 1735120, EP-AT: 23.02.2005) 

Lebensmittelverpackung. Alcan Technology 

& Management Ltd., Neuhausen am Rheinfall, 

CH. (B65D 85/72, OS 10 2009 048 417, AT: 

06.10.2009) 

Vorrichtung zur gerichteten Erstarrung von 

Gusstücken. Alcoa Inc., Pittsburgh, PA 15212- 

5858, US. (B22D 7/02, EPA 2295167, EP-AT: 

12.07.2006) 

Wärmegedämmtes Verbundprofil mit Isolierkern 

sowie Verfahren zur Herstellung eines 

solchen Verbundprofils. Alcoa Aluminium 

Deutschland, Inc., 58642 Iserlohn, DE. (E06B 

3/263, PS 50 2008 000 451, EP 2080864, EP-AT: 

16.01.2008) 

Magnesiumlegierung. TechMag AG, Baar, CH. 

(C22C 23/00, GM 202 02 591, AT: 20.02.2002) 

Vorrichtung zur Aufnahme einer Seite einer 

Fensterbank. Corus Aluminium Profiltechnik 

GmbH, 88267 Vogt, DE. (E06B 1/70, GM 20 2004 

019 812, AT: 23.12.2004) 

Verfahren zur Koextrusion von Metallprodukten 

und Matrize zur Durchführung 

des Verfahrens. Aleris Aluminum Bitterfeld 

GmbH, 06749 Bitterfeld, DE. (B21C 23/22, EPA 

2289641, EP-AT: 24.08.2009) 

Verfahren zum Gießen eines Verbundblocks. 

Aleris Aluminum Koblenz GmbH, 56070 

Koblenz, DE. (B22D 19/00, EPA 2293894, WO 

2010/000553, EP-AT: 03.06.2009, WO-AT: 

03.06.2009) 

Verfahren zur Herstellung einer integrierten 

monolithischen Aluminiumstruktur und Aluminiumprodukt 

aus dieser Struktur hergestellt. 

Aleris Aluminum Koblenz GmbH, 56070 

Koblenz, DE. (C22F 1/04, OS 10 2004 010 700, 

AT: 04.03.2004) 

Fortsetzung in ALUMINIUM 7-8/2011 


LIEFERVERZEICHNIS 

1 

Smelting technology 

Hüttentechnik 

1.1 Raw materials 

1.2 Storage facilities for smelting 

1.3 Anode production 

1.4 Anode rodding 

1.4.1 Anode baking 

1.4.2 Anode clearing 

1.4.3 Fixing of new anodes to the 

anodes bars 

1.5 Casthouse (foundry) 

1.6 Casting machines 

1.7 Current supply 

1.8 Electrolysis cell (pot) 

1.9 Potroom 

1.10 Laboratory 

1.11 Emptying the cathode shell 

1.12 Cathode repair shop 

1.13 Second-hand plant 

1.14 Aluminium alloys 

1.15 Storage and transport 

1.16 Smelting manufactures 

1.2 Storage facilities for 

smelting 

Lagermöglichkeiten i.d. Hütte 

FLSmidth MÖLLER GmbH 

Haderslebener Straße 7 

D-25421 Pinneberg 

Telefon: 04101 788-0 

Telefax: 04101 788-115 

E-Mail: moeller@flsmidth.com 

Internet: www.flsmidthmoeller.com 

Kontakt: Herr Dipl.-Ing. Timo Letz 

Outotec GmbH 

Albin-Köbis-Str. 8, D-51147 Köln 

Phone: +49 (0) 2203 / 9921-0 

E-mail: aluminium@outotec.com 

www.outotec.com 

� Bulk materials Handling 

from Ship to Cell 

Bulk materials Handling from Ship to Cell 

www.coperion.com 

mailto: info.cc-mh@coperion.com 

� Conveying systems bulk materials 

Förderanlagen für Schüttgüter 

(Hüttenaluminiumherstellung) 


Internet: www.flsmidthmoeller.com 

see Storage facilities for smelting 1.2 

1.1 Rohstoffe 

1.2 Lagermöglichkeiten in der Hütte 

1.3 Anodenherstellung 

1.4 Anodenschlägerei 

1.4.1 Anodenbrennen 

1.4.2 Anodenschlägerei 

1.4.3 Befestigen von neuen Anoden 

an der Anodenstange 

1.5 Gießerei 

1.6 Gießmaschinen 

1.7 Stromversorgung 

1.8 Elektrolyseofen 

1.9 Elektrolysehalle 

1.10 Labor 

1.11 Ofenwannenentleeren 

1.12 Kathodenreparaturwerkstatt 

1.13 Gebrauchtanlagen 

1.14 Aluminiumlegierungen 

1.15 Lager und Transport 

1.16 Hüttenerzeugnisse 

� Unloading/Loading equipment 

Entlade-/Beladeeinrichtungen 


www.flsmidthmoeller.com 


ALUMINA AND PET COKE SHIPUNLOADERS 

Contact: Andreas Haeuser, ha@neuero.de 

1.3 Anode production 

Anodenherstellung 


Solios Carbone – France 

www.fivesgroup.com 

Storvik AS 

Industriveien 13 

6600 SUNNDALSØRA/NORWAY 

Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55 

www.storvik.no | storvik@storvik.no 

� Auto firing systems 

Automatische Feuerungssysteme 

RIEDHAMMER GmbH 

D-90411 Nürnberg 

Phone: +49 (0) 911 5218 0, Fax: -5218 231 

E-Mail: thomas.janousch@riedhammer.de 

Internet: www.riedhammer.de 

� Hydraulic presses for prebaked 

anodes / Hydraulische Pressen zur 

Herstellung von Anoden 

LAEIS GmbH 

Am Scheerleck 7, L-6868 Wecker, Luxembourg 

Phone: +352 27612 0 

Fax: +352 27612 109 

E-Mail: info@laeis-gmbh.com 

Internet: www.laeis-gmbh.com 

Contact: Dr. Alfred Kaiser 

� Anode Technology & 

Mixing Equipment 

Buss ChemTech AG, Switzerland 

Phone: +4161 825 64 62 

E-Mail: info@buss-ct.com 

Internet: www.buss-ct.com 


� Mixing Technology for 

Anode pastes 

Mischtechnologie für Anodenmassen 

Buss AG 

CH-4133 Pratteln 

Phone: +41 61 825 66 00 

E-Mail: info@busscorp.com 

Internet: www.busscorp.com 

� Open top and closed 

type baking furnaces 

Offene und geschlossene Ringöfen 

RIEDHAMMER GmbH 

D-90411 Nürnberg 

Phone: +49 (0) 911 5218 0, Fax: -5218 231 

E-Mail: thomas.janousch@riedhammer.de 

Internet: www.riedhammer.de 

1.4 Anode rodding 

Anodenanschlägerei 


� Removal of bath residues from 

the surface of spent anodes 

Entfernen der Badreste von der Ober - 

fläche der verbrauchten Anoden 

GLAMA Maschinenbau GmbH 

Hornstraße 19 

D-45964 Gladbeck 

Telefon 02043 / 9738-0 

Telefax 02043 / 9738-50 

� Transport of finished anode 

elements to the pot room 

Transport der fertigen Anodenelemente 

in Elektrolysehalle 

Hovestr. 10 . D-48431 Rheine 

Telefon + 49 (0) 59 7158-0 

Fax + 49 (0) 59 7158-209 

E-Mail info@windhoff.de 

Internet www.windhoff.de 

1.4.1 Anode baking 

Anodenbrennen 

� Anode charging/Anodenchargieren 

SERMAS INDUSTRIE 

E-Mail: sermas@sermas.com 

see Casting Machines 1.6 

� Anode storage/Anodenlager 




1.4.2 Anode clearing 

Anodenschlägerei 

� Separation of spent anodes 

from the anode bars 

Trennen von den Anodenstangen 




1.4.3 Fixing of new anodes 

to the anodes bars 

Befestigen von neuen 

Anoden a. d. Anodenstange 

� Fixing the nipples to the 

anodes by casting in 

Befestigen der Nippel mit der 

Anode durch Eingießen 




1.5 Casthouse (foundry) 

Gießerei 

Hampshire House, High Street, Kingswinford, 

West Midlands DY6 8AW, UK 

Tel.: +44 (0) 1384 279132 

Fax: +44 (0) 1384 291211 

E-Mail: sales@mechatherm.co.uk 

www.mechatherm.com 

HERTWICH ENGINEERING GmbH 

Maschinen und Industrieanlagen 

Weinbergerstraße 6, A-5280 Braunau am Inn 

Phone +437722/806-0 

Fax +437722/806-122 

E-Mail: info@hertwich.com 

Internet: www.hertwich.com 

INOTHERM INDUSTRIEOFEN- 

UND WÄRMETECHNIK GMBH 

Konstantinstraße 1a 

D 41238 Mönchengladbach 

Telefon +49 (02166) 987990 

Telefax +49 (02166) 987996 

E-Mail: info@inotherm-gmbh.de 

Internet: www.inotherm-gmbh.de 

see Equipment and accessories 3.1 

Stopinc AG 

Bösch 83 a 

CH-6331 Hünenberg 

Tel. +41/41-785 75 00 

Fax +41/41-785 75 01 

E-Mail: interstop@stopinc.ch 

Internet: www.stopinc.ch 

SUPPLIERS DIRECTORY 

� Degassing, filtration and 

grain refinement 

Entgasung, Filtern, Kornfeinung 

Drache Umwelttechnik 

GmbH 

Werner-v.-Siemens-Straße 9/24-26 

D 65582 Diez/Lahn 

Telefon 06432/607-0 

Telefax 06432/607-52 

Internet: www.drache-gmbh.de 

Gautschi 

Engineering GmbH 

see Casting equipment 3.1 

� Dross skimming of liquid metal 

Abkrätzen des Flüssigmetalls 


see Anode rodding 1.4 

� Dross skimming of the melt 

Abkrätzen der Schmelze 


see Casting machines 1.6 

� Furnace charging with 

molten metal 

Ofenbeschickung mit Flüssigmetall 



� Melting/holding/casting furnaces 

Schmelz-/Halte- und Gießöfen 

Gautschi 



Solios Thermal UK 



see Casthouse (foundry) 1.5 

Sistem Teknik Ltd. Sti. 

DES San. Sit. 102 SOK No: 6/8 

Y.Dudullu, TR-34775 Istanbul/Turkey 

Tel.: +90 216 420 86 24 

Fax: +90 216 420 23 22 

E-Mail: info@sistemteknik.com 

Internet: www.sistemteknik.com 

� Metal treatment in the 

holding furnace 

Metallbehandlung in Halteöfen 

Gautschi 





� Transfer to the casting furnace 

Überführung in Gießofen 




GmbH 



Telefon 06432/607-0 

Telefax 06432/607-52 

Internet: www.drache-gmbh.de 

Gautschi 



Windhoff Bahn- und 

Anlagentechnik GmbH 


� Transport of liquid metal 

to the casthouse 

Transport v. Flüssigmetall in Gießereien 



MARX GmbH & Co. KG 

www.marx-gmbh.de 

see Melt operations 4.13 




� Treatment of casthouse 

off gases 

Behandlung der Gießereiabgase 

Gautschi 




www.solios.com 


Gießmaschinen 

GAPCast TM: the Swiss casting solution 

see Casting machines and equipment 4.7 


see Smelting technology 1.5 

RIHS ENGINEERING AG 

see Casting machines and equipment 4.7 

� Pig casting machines (sow casters) 

Masselgießmaschine (Sowcaster) 

Gautschi 




� Rolling and extrusion ingot 

and T-bars 

Formatgießerei (Walzbarren oder 

Pressbolzen oder T-Barren) 

Gautschi 





� Horizontal continuous casting 

Horizontales Stranggießen 

Gautschi 





� Scales / Waagen 

Gautschi 





� Sawing / Sägen 

Gautschi 





343 Chemin du Stade 

38210 Saint Quentin sur Isère 

Tel. +33 (0) 476 074 242 

Fax +33 (0) 476 936 776 


Internet: www.sermas.com 

� Heat treatment of extrusion 

ingot (homogenisation) 

Formatebehandlung (homogenisieren) 

Gautschi 





see Billet Heating Furnaces 1.5 

� Vertical semi-continuous DC 

casting / Vertikales Stranggießen 

Gautschi 



Wagstaff, Inc. 

3910 N. Flora Rd. 

Spokane, WA 99216 USA 

+1 509 922 1404 phone 

+1 509 924 0241 fax 

E-Mail: info@wagstaff.com 

Internet: www.wagstaff.com 

1.8 Electrolysis cell (pot) 

Elektrolyseofen 

� Bulk materials Handling 

from Ship to Cell 

Bulk materials Handling from Ship to Cell 

www.coperion.com 

mailto: info.cc-mh@coperion.com 

� Calcium silicate boards 

Calciumsilikatplatten 

Promat GmbH – Techn. Wärmedämmung 

Scheifenkamp 16, D-40878 Ratingen 

Tel. +49 (0) 2102 / 493-0, Fax -493 115 

verkauf3@promat.de, www.promat.de 

� Exhaust gas treatment 

Abgasbehandlung 

Solios Environnement 


� Pot feeding systems 

Beschickungseinrichtungen 

für Elektrolysezellen 


www.flsmidthmoeller.com 


1.9 Potroom 

Elektrolysehalle 

T.T. Tomorrow Technology S.p.A. 

Via dell’Artigianato 18 

Due Carrare, Padova 35020, Italy 

Telefon +39 049 912 8800 

Telefax +39 049 912 8888 

E-Mail: gmagarotto@tomorrowtechnology.it 

Contact: Giovanni Magarotto 


� Anode changing machine 

Anodenwechselmaschine 



� Anode transport equipment 

Anoden Transporteinrichtungen 



� Crustbreakers / Krustenbrecher 



� Dry absorption units for 

electrolysis exhaust gases 

Trockenabsorptionsanlage für 

Elektrolyseofenabgase 

Solios Environnement 


� Tapping vehicles/Schöpffahrzeuge 



2 Extrusion 

Strangpressen 

2.1 Extrusion billet preparation 

2.1.1 Extrusion billet production 

2.2 Extrusion equipment 

2.3 Section handling 

2.4 Heat treatment 

2.5 Measurement and control equipment 

2.6 Die preparation and care 

2.7 Second-hand extrusion plant 

2.8 Consultancy, expert opinion 

2.9 Surface finishing of sections 

2.10 Machining of sections 

2.11 Equipment and accessories 

2.12 Services 

2.1 Extrusion billet preparation 

Pressbolzenbereitstellung 

� Billet heating furnaces 

Öfen zur Bolzenerwärmung 

Am großen Teich 16+27 

D-58640 Iserlohn 

Tel. +49 (0) 2371 / 4346-0 

Fax +49 (0) 2371 / 4346-43 

E-Mail: verkauf@ias-gmbh.de 

Internet: www.ias-gmbh.de 

www.alu-web.de 

1.11 Emptying the cathode shell 

Ofenwannenentleeren 

� Cathode bar casting units 

Kathodenbarreneingießanlage 



1.14 Aluminium Alloys 

Aluminiumlegierungen 

RHEINFELDEN ALLOYS GmbH & Co. KG 

A member of ALUMINIUM RHEINFELDEN Group 

Postfach 1703, 79607 Rheinfelden 

Tel.: +49 7623 93-490 

Fax: +49 7623 93-546 

E-Mail: alloys@rheinfelden-alloys.eu 

Internet: www.rheinfelden-alloys.eu 

2.1 Pressbolzenbereitstellung 

2.1.1 Pressbolzenherstellung 

2.2 Strangpresseinrichtungen 

2.3 Profilhandling 

2.4 Wärmebehandlung 

2.5 Mess- und Regeleinrichtungen 

2.6 Werkzeugbereitstellung und -pflege 

2.7 Gebrauchte Strangpressanlagen 

2.8 Beratung, Gutachten 

2.9 Oberflächenveredlung von Profilen 

2.10 Profilbearbeitung 

2.11 Ausrüstungen und Hilfsmittel 

2.12 Dienstleistungen 





DES San. Sit. 102 SOK No: 6/8 

Y. Dudullu, TR-34775 Istanbul/Turkey 

Tel.: +90 216 420 86 24 

Fax: +90 216 420 23 22 

E-Mail: info@sistemteknik.com 

Internet: www.sistemteknik.com 


1.15 Storage and transport 

Lager und Transport 

SMS Siemag AG 

see Rolling mill technology 3.0 

1.16 Smelting manufactories 

Hüttenerzeugnisse 

� Rolling ingots 

Walzbarren 

Alcan Aluminium Valais SA 

CH-3960 Sierre 

Telefon: 0041 27 / 4575111 

Telefax: 0041 27 / 4576425 

2.1.1 Extrusion billet 

production 

Pressbolzenherstellung 



� Billet transport and storage 

equipment 

Bolzen-Transport- u. Lagereinricht. 



See Casting Machines 1.6 




2.2 Extrusion equipment 

Strangpresseinrichtungen 



Oilgear Towler GmbH 

Im Gotthelf 8 

D 65795 Hattersheim 

Tel. +49 (0) 6145 3770 

Fax +49 (0) 6145 30770 

E-Mail: info@oilgear.de 

Internet: www.oilgear.de 

SMS Meer GmbH 

Schloemann Extrusion 

Ohlerkirchweg 66 

41069 Mönchengladbach, Germany 

Tel. +49 (0) 2161 350-0 

Fax +49 (0) 2161 350-1667 

E-Mail: info@sms-meer.com 

Internet: www.sms-meer.com 

� Containers / Rezipienten 

SMS Meer GmbH 

see Extrusion equipment 2.2 

� Press control systems 

Pressensteuersysteme 

Oilgear Towler GmbH 

see Extrusion Equipment 2.2 

SMS Meer GmbH 


� Temperature measurement 

Temperaturmessung 

SMS Meer GmbH 


� Heating and control 

equipment for intelligent 

billet containers 

Heizungs- und Kontrollausrüstung 

für intelligente Blockaufnehmer 




2.3 Section handling 

Profilhandling 

� Packaging equipment 

Verpackungseinrichtungen 

Vollert Anlagenbau 

GmbH + Co. KG 

Stadtseestraße 12 

D-74189 Weinsberg 

Tel. +49 (0) 7134 / 52-220 

Fax +49 (0) 7134 / 52-222 

E-Mail intralogistik@vollert.de 

Internet www.vollert.de 

� Puller equipment 

Ausziehvorrichtungen/Puller 

SMS Meer GmbH 


� Section cooling 

Profilkühlung 

SMS Meer GmbH 


� Section saws 

Profilsägen 

SMS Meer GmbH 


� Section store equipment 

Profil-Lagereinrichtungen 

KASTO Maschinenbau GmbH & Co. KG 

Industriestr. 14, D-77855 Achern 

Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300 

kasto@kasto.de / www.kasto.de 

Hersteller von Band- und Kreissägemaschinen 

sowie Langgut- und Blechlagersystemen 


GmbH + Co. KG 

see Packaging equipment 2.3 

� Section transport equipment 

Profiltransporteinrichtungen 

SMS Meer GmbH 


Nijverheidsweg 3 

NL-7071 CH Ulft Netherlands 

Tel.: +31 315 641352 

Fax: +31 315 641852 

E-Mail: info@unifour.nl 

Internet: www.unifour.nl 

Sales Contact: Paul Overmans 

� Stackers / Destackers 

Stapler / Entstapler 

SMS Meer GmbH 


� Stretching equipment 

Reckeinrichtungen 

SMS Meer GmbH 


� Transport equipment for 

extruded sections 

Transporteinrichtungen 

für Profilabschnitte 


GmbH + Co. KG 


Hier könnte Ihr 

Bezugsquellen- 

Eintrag 

stehen. 

Rufen Sie an: 

Tel. 0511 / 73 04-148 

Beate Schaefer 


2.4 Heat treatment 

Wärmebehandlung 

BSN Thermprozesstechnik GmbH 

Kammerbruchstraße 64 

D-52152 Simmerath 

Tel. 02473-9277-0 · Fax: 02473-9277-111 

info@bsn-therm.de · www.bsn-therm.de 

Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, 

Buntmetallen und Stählen 




� Heat treatment furnaces 

Wärmebehandlungsöfen 





� Homogenising furnaces 

Homogenisieröfen 




2.5 Measurement and 

control equipment 

Mess- und Regeleinrichtungen 

� Extrusion plant control systems 

Presswerkssteuerungen 

SMS Meer GmbH 


2.6 Die preparation and care 

Werkzeugbereitstellung 

und -pflege 

� Die heating furnaces 

Werkzeuganwärmöfen 




2.11 Equipment and 

accessories 

Ausrüstungen und 

Hilfsmittel 



see Melt operations 4.13 � Inductiv heating equipment 

Induktiv beheizte 

Erwärmungseinrichtungen 



Tel.: +31 315 641352 

Fax: +31 315 641852 




Could not find your 

„keywords“? 

Please ask for 

our complete 

„Supply sources for the 

aluminium industry“. 

E-Mail: 

anzeigen@giesel.de 

2.7 Second-hand 

extrusion plant 

Gebr. Strangpressanlagen 

Qualiteam International/ExtruPreX 

Champs Elyséesweg 17, NL-6213 AA Maastricht 

Tel. +31-43-3 25 67 77 

Internet: www.extruprex.com 

Am großen Teich 16+27 

D-58640 Iserlohn 

Tel. +49 (0) 2371 / 4346-0 

Fax +49 (0) 2371 / 4346-43 

E-Mail: verkauf@ias-gmbh.de 

Internet: www.ias-gmbh.de 


Bezugsquellen-Eintrag 

stehen. 

Rufen Sie an: 

Tel. 0511 / 73 04-148 


� Ageing furnace for extrusions 

Auslagerungsöfen für 

Strangpressprofile 




Tel.: +31 315 641352 

Fax: +31 315 641852 






3 

Rolling mill technology 

Walzwerktechnik 

3.1 Casting equipment 

3.2 Rolling bar machining 

3.3 Rolling bar furnaces 

3.4 Hot rolling equipment 

3.5 Strip casting units and accessories 

3.6 Cold rolling equipment 

3.7 Thin strip / foil rolling plant 

3.8 Auxiliary equipment 

3.9 Adjustment devices 

3.10 Process technology / 

Automation technology 

3.11 Coolant / lubricant preparation 

3.12 Air extraction systems 

3.13 Fire extinguishing units 

3.14 Storage and dispatch 

3.15 Second-hand rolling equipment 

3.16 Coil storage systems 

3.17 Strip Processing Lines 

3.18 Productions Management Systems 

3.0 Rolling mill technology 

Walzwerktechnik 

see Cold rolling units / complete plants 3.6 

SMS Siemag Aktiengesellschaft 

Eduard-Schloemann-Straße 4 

40237 Düsseldorf, Germany 

Telefon: +49 (0) 211 881-0 

Telefax: +49 (0) 211 881-4902 

E-Mail: communications@sms-siemag.com 

Internet: www.sms-siemag.com 

Geschäftsbereiche: 

Warmflach- und Kaltwalzwerke 

Wiesenstraße 30 

57271 Hilchenbach-Dahlbruch, Germany 

Telefon: +49 (0) 2733 29-0 

Telefax: +49 (0) 2733 29-2852 

Bandanlagen 

Walder Straße 51-53 

40724 Hilden, Germany 

Telefon: +49 (0) 211 881-5100 

Telefax: +49 (0) 211 881-5200 

Elektrik + Automation 

Ivo-Beucker-Straße 43 


Telefon: +49 (0) 211 881-5895 

Telefax: +49 (0) 211 881-775895 

Graf-Recke-Straße 82 


Telefon: +49 (0) 211 881-0 

Telefax: +49 (0) 211 881-4902 

3.1 Gießanlagen 

3.2 Walzbarrenbearbeitung 

3.3 Walzbarrenvorbereitung 

3.4 Warmwalzanlagen 

3.5 Bandgießanlagen und Zubehör 

3.6 Kaltwalzanlagen 

3.7 Feinband-/Folienwalzwerke 

3.8 Nebeneinrichtungen 

3.9 Adjustageeinrichtungen 

3.10 Prozesstechnik / 

Automatisierungstechnik 

3.11 Kühl-/Schmiermittel-Aufbereitung 

3.12 Abluftsysteme 

3.13 Feuerlöschanlagen 

3.14 Lagerung und Versand 

3.15 Gebrauchtanlagen 


3.17 Bandprozesslinien 

3.18 Produktions Management Systeme 

3.1 Casting equipment 

Gießanlagen 



� Electromagnetic Stirrer 

Elektromagnetische Rührer 



� Filling level indicators and controls 

Füllstandsanzeiger und -regler 

Gautschi 




� Melting and holding furnaces 

Schmelz- und Warmhalteöfen 

Gautschi Engineering GmbH 

Konstanzer Straße 37 

CH 8274 Tägerwilen 

Telefon +41 71 666 66 66 

Telefax +41 71 666 66 77 

E-Mail: info@gautschi.cc 

Internet: www.gautschi.cc 

Kontakt: Sales Departement 


LOI Thermprocess GmbH 

Am Lichtbogen 29 

D-45141 Essen 

Germany 

Telefon +49 (0) 201 / 18 91-1 

Telefax +49 (0) 201 / 18 91-321 

E-Mail: info@loi-italimpianti.de 

Internet: www.loi-italimpianti.com 



� Melt purification units 

Schmelzereinigungsanlagen 

Gautschi 



� Metal filters / Metallfilter 

Gautschi 



� Metal pumps / Metallpumpen 


www.solios.com 

3.2 Rolling bar machining 

Walzbarrenbearbeitung 

� Band saws / Bandsägen 

SMS Meer GmbH 



� Slab milling machines 

Barrenfräsmaschinen 

SMS Meer GmbH 


3.3 Rolling bar furnaces 

Walzbarrenvorbereitung 


see Heat Treatment 2.4 

� Annealing furnaces 

Glühöfen 

EBNER Industrieofenbau Ges.m.b.H. 

Ruflinger Str. 111, 4060 Leonding/Austria 

Tel. +43 / 732 / 6868 

E-Mail: sales@ebner.cc 

Internet: www.ebner.cc 

Gautschi 



schwartz GmbH 




� Bar heating furnaces 

Barrenanwärmanlagen 

see Heat treatment 2.4 

EBNER Industrieofenbau Ges.m.b.H. 

see Annealing furnaces 3.3 

Gautschi 



� Homogenising furnaces 

Homogenisieröfen 

Gautschi 







� Roller tracks 

Rollengänge 

Gautschi 



3.4 Hot rolling equipment 

Warmwalzanlagen 

Achenbach Buschhütten GmbH 

Siegener Str. 152, D-57223 Kreuztal 

Tel. +49 (0) 2732/7990, info@achenbach.de 

Internet: www.achenbach.de 


� Coil transport systems 

Bundtransportsysteme 


GmbH + Co. KG 





� Drive systems / Antriebe 

SMS Siemag AG 


� Rolling mill modernisation 

Walzwerksmodernisierung 

SMS Siemag AG 


� Spools / Haspel 

SMS Siemag AG 


� Hot rolling units / 

complete plants 

Warmwalzanlagen/Komplettanlagen 

SMS Siemag AG 



3.6 Cold rolling equipment 

Kaltwalzanlagen 






see Heat Treatment 2.4 

� Coil annealing furnaces 

Bundglühöfen 

Gautschi 




� Coil transport systems 

Bundtransportsysteme 


GmbH + Co. KG 





� Cold rolling units / 

complete plants 

Kaltwalzanlagen/Komplettanlagen 

SMS Siemag AG 


� Drive systems / Antriebe 

SMS Siemag AG 




� Heating furnaces / Anwärmöfen 

Gautschi 



� Process optimisation systems 

Prozessoptimierungssysteme 

Gautschi 



� Process simulation 

Prozesssimulation 

Gautschi 



SMS Siemag AG 


� Roll exchange equipment 

Walzenwechseleinrichtungen 

SMS Siemag AG 



GmbH + Co. KG 





� Rolling mill modernization 

Walzwerkmodernisierung 






� Slitting lines-CTL 

Längs- und Querteilanlagen 


� Strip shears/Bandscheren 


SMS Siemag AG 


� Trimming equipment 

Besäumeinrichtungen 


SMS Siemag AG 


3.7 Thin strip / 

foil rolling plant 

Feinband-/Folienwalzwerke 






� Coil annealing furnaces 

Bundglühöfen 

Gautschi 




schwartz GmbH 

see Cold colling equipment 3.6 

� Heating furnaces 

Anwärmöfen 

Gautschi 






� Thin strip / foil rolling mills / 

complete plant 

Feinband- / Folienwalzwerke / 

Komplettanlagen 

SMS Siemag AG 


� Rolling mill modernization 

Walzwerkmodernisierung 





3.9 Adjustment devices 

Adjustageeinrichtungen 

� Sheet and plate stretchers 

Blech- und Plattenstrecker 

SMS Meer GmbH 


� Cable sheathing presses 

Kabelummantelungspressen 

SMS Meer GmbH 


� Cable undulating machines 

Kabelwellmaschinen 

SMS Meer GmbH 


� Transverse cutting units 

Querteilanlagen 




3.10 Process technology / 

Automation technology 

Prozesstechnik / 

Automatisierungstechnik 

� Process control technology 

Prozessleittechnik 

SMS Siemag AG 





� Strip flatness measurement 

and control equipment 

Bandplanheitsmess- und 

-regeleinrichtungen 

ABB Automation 

Force Measurement 

S-72159 Västeras, Sweden 

Phone: +46 21 325 000 

Fax: +46 21 340 005 

E-Mail: pressductor@se.abb.com 

Internet: www.abb.com/pressductor 





SMS Siemag AG 


� Strip thickness measurement 

and control equipment 

Banddickenmess- und 

-regeleinrichtungen 




Phone: +46 21 325 000 

Fax: +46 21 340 005 







SMS Siemag AG 


� Strip Tension 

Measurement equipment 

Bandzugmesseinrichtungen 




Phone: +46 21 325 000 

Fax: +46 21 340 005 



� Roll Force 


Walzkraftmesseinrichtungen 




Phone: +46 21 325 000 

Fax: +46 21 340 005 



� Strip Width & Position 


Bandbreiten- und 

Bandlaufmesseinrichtungen 




Phone: +46 21 325 000 

Fax: +46 21 340 005 



3.11 Coolant / lubricant 

preparation 

Kühl-/Schmiermittel- 

Aufbereitung 


� Rolling oil recovery and 

treatment units 

Walzöl-Wiederaufbereitungsanlagen 

SMS Siemag AG 


� Filter for rolling oils and 

emulsions 

Filter für Walzöle und Emulsionen 






� Rolling oil rectification units 

Walzölrektifikationsanlagen 





SMS Siemag AG 


3.12 Air extraction systems 

Abluft-Systeme 


� Exhaust air purification 

systems (active) 

Abluft-Reinigungssysteme (aktiv) 





SMS Siemag AG 


3.14 Storage and dispatch 

Lagerung und Versand 

SMS Siemag AG 



Bezugsquellen-Eintrag 

stehen. 

Rufen Sie an: 

Tel. 0511 / 73 04-148 





Bundlagersysteme 

SMS Siemag AG 



GmbH + Co. KG 


3.17 Strip Processing Lines 

Bandprozesslinien 

� Colour Coating Lines 

Bandlackierlinien 

www.bwg-online.com 

see Strip Processing Lines 3.17 

4 Foundry 

Gießerei 

4.1 Work protection and ergonomics 

4.2 Heat-resistant technology 

4.3 Conveyor and storage technology 

4.4 Mould and core production 

4.5 Mould accessories and accessory materials 

4.6 Foundry equipment 

4.7 Casting machines and equipment 

4.8 Handling technology 

4.9 Construction and design 

4.10 Measurement technology and materials testing 

4.11 Metallic charge materials 

4.12 Finshing of raw castings 

4.13 Melt operations 

4.14 Melt preparation 

4.15 Melt treatment devices 

4.16 Control and regulation technology 

4.17 Environment protection and disposal 

4.18 Dross recovery 

4.19 Gussteile 

4.2 Heat-resistent technology 

Feuerfesttechnik 

� Refractories / Feuerfeststoffe 

Promat GmbH – Techn. Wärmedämmung 

Scheifenkamp 16, D-40878 Ratingen 

Tel. +49 (0) 2102 / 493-0, Fax -493 115 

verkauf3@promat.de, www.promat.de 

� Lithographic Sheet Lines 

Lithografielinien 




� Stretch Levelling Lines 

Streckrichtanlagen 



� Strip Annealing Lines 

Bandglühlinien 



4.1 Arbeitsschutz und Ergonomie 

4.2 Feuerfesttechnik 

4.3 Förder- und Lagertechnik 

4.4 Form- und Kernherstellung 

4.5 Formzubehör, Hilfsmittel 

4.6 Gießereianlagen 

4.7 Gießmaschinen und Gießeinrichtungen 

4.8 Handhabungstechnik 

4.9 Konstruktion und Design 

4.10 Messtechnik und Materialprüfung 

4.11 Metallische Einsatzstoffe 

4.12 Rohgussnachbehandlung 

4.13 Schmelzbetrieb 

4.14 Schmelzvorbereitung 

4.15 Schmelzebehandlungseinrichtungen 

4.16 Steuerungs- und Regelungstechnik 

4.17 Umweltschutz und Entsorgung 

4.18 Schlackenrückgewinnung 

4.19 Cast parts 

4.3 Conveyor and storage 

technology 

Förder- und Lagertechnik 


GmbH + Co. KG 


� Strip Processing Lines 

Bandprozesslinien 

BWG Bergwerk- und Walzwerk- 

Maschinenbau GmbH 

Mercatorstraße 74 – 78 

D-47051 Duisburg 

Tel.: +49 (0) 203-9929-0 

Fax: +49 (0) 203-9929-400 

E-Mail: bwg@bwg-online.de 

Internet: www.bwg-online.com 

3.18 Production 

Management systems 

Produktions Management 

Systeme 

PSI Metals Non Ferrous GmbH 

Software Excellence in Metals 

Carlo-Schmid-Str. 12, D-52146 Würselen 

Tel.: +49 (0) 2405 4135-0 

info@psimetals.de, www.psimetals.com 

4.5 Mold accessories and 

accessory materials 

Formzubehör, Hilfmittel 

� Fluxes 

Flussmittel 

Solvay Fluor GmbH 

Hans-Böckler-Allee 20 

D-30173 Hannover 

Telefon +49 (0) 511 / 857-0 

Telefax +49 (0) 511 / 857-2146 

Internet: www.solvay-fluor.de 


4.6 Foundry equipment 

Gießereianlagen 



� Casting machines 

Gießmaschinen 





Wärmebehandlungsöfen 

ELPO GmbH 

Kuchengrund 18 

71522 Backnang 

Telefon 07191 9572-0 

Telefax 07191 9572-29 

E-Mail: info@elpo.de 

Internet: www.elpo.de 



and equipment 

Gießereimaschinen 

und Gießeinrichtungen 

GAPCast TM: the Swiss casting solution 

Casting Technology / Automation 

Tel.: +41 27 455 57 14 

E-Mail: info@gap-engineering.ch 

Internet: www.gap-engineering.ch 



Molten Metall Level Control 

Ostra Hamnen 7 

SE-430 91 Hono / Schweden 

Tel.: +46 31 764 5520, Fax: +46 31 764 5529 

E-Mail: info@precimeter.com 

Internet: www.precimeter.com 

Sales contact: Jan Strömbeck 

Competence in EMC and ASC casting 

RIHS ENGINEERING AG 

CH-3123 Belp, P.O. Box 197 

Phone: +41 31 812-0025, Fax: -0026 

Mail: rihs@maschko.ch 


� Mould parting agents 

Kokillentrennmittel 

Schröder KG 

Schmierstofftechnik 

Postfach 1170 

D-57251 

Freudenberg 

Tel. 02734/7071 

Fax 02734/20784 

www.schroeder-schmierstoffe.de 

4.8 Handling technology 

Handhabungstechnik 


GmbH + Co. KG 


� Manipulators 

Manipulatoren 


� Continuous ingot casting 

lines and aluminium rod lines 

Kokillengieß- und Aluminiumdraht-Anlagen 





4.11 Metallic charge 

materials 

Metallische Einsatzstoffe 

� Aluminium alloys 

Aluminiumlegierungen 

METALLHANDELSGESELLSCHAFT 

SCHOOF & HASLACHER MBH & CO. KG 

Postfach 600714, D 81207 München 

Telefon 089/829133-0 

Telefax 089/8201154 

E-Mail: info@metallhandelsgesellschaft.de 

Internet: www.metallhandelsgesellschaft.de 

� Pre alloys / Vorlegierungen 

METALLHANDELSGESELLSCHAFT 

SCHOOF & HASLACHER MBH & CO. KG 

Postfach 600714, D 81207 München 

Telefon 089/829133-0 

Telefax 089/8201154 

E-Mail: info@metallhandelsgesellschaft.de 

Internet: www.metallhandelsgesellschaft.de 

� Recycling / Recycling 

Chr. Otto Pape GmbH 

Aluminiumgranulate 

Berliner Allee 34 

D-30855 Langenhagen 

Tel:+49(0)511 786 32-0 Fax: -32 

Internet: www.papemetals.com 

E-Mail: info@papemetals.com 

4.13 Melt operations 

Schmelzbetrieb 




Wärmebehandlungsanlagen 




� Melting furnaces 

Schmelzöfen 

Büttgenbachstraße 14 

D-40549 Düsseldorf/Germany 

Tel.: +49 (0) 211 / 5 00 91-43 

Fax: +49 (0) 211 / 50 13 97 

E-Mail: info@bloomeng.de 

Internet: www.bloomeng.com 

Sales Contact: Klaus Rixen 

Gautschi 







Lilienthalstr. 6-18 

D-58638 Iserhohn 

Tel.: +49 (0) 2371 / 2105-0, Fax: -11 

E-Mail: info@marx-gmbh.de 

Internet: www.marx-gmbh.de 

� Holding furnaces 

Warmhalteöfen 

Büttgenbachstraße 14 

D-40549 Düsseldorf/Germany 

Tel.: +49 (0) 211 / 5 00 91-43 

Fax: +49 (0) 211 / 50 13 97 

E-Mail: info@bloomeng.de 

Internet: www.bloomeng.com 

Sales Contact: Klaus Rixen 

Gautschi 





Wärmebehandlungsanlagen 

Gautschi 






4.14 Melt preparation 

Schmelzvorbereitung 

� Degassing, filtration 

Entgasung, Filtration 


GmbH 



Telefon 06432/607-0 

Telefax 06432/607-52 

Internet: http://www.drache-gmbh.de 

Gautschi 



� Melt treatment agents 

Schmelzebehandlungsmittel 

Gautschi 



5 

6 

4.15 Melt treatment devices 

Schmelzbehandlungseinrichtungen 

Metaullics Systems Europe B.V. 

Ebweg 14 

NL-2991 LT Barendrecht 

Tel. +31-180/590890 

Fax +31-180/551040 

E-Mail: info@metaullics.nl 

Internet: www.metaullics.com 

Materials and Recycling 

Werkstoffe und Recycling 

4.17 Environment protection 

and disposal 

Umweltschutz und 

Entsorgung 

� Dust removal 

Entstaubung 

NEOTECHNIK GmbH 

Entstaubungsanlagen 

Postfach 110261, D-33662 Bielefeld 

Tel. 05205/7503-0, Fax 05205/7503-77 

info@neotechnik.com, www.neotechnik.com 

� Granulated aluminium 


Chr. Otto Pape GmbH 


Berliner Allee 34 

D-30855 Langenhagen 

Tel:+49(0)511 786 32-0 Fax: -32 

Internet: www.papemetals.com 

E-Mail: info@papemetals.com 

Machining and Application 

Bearbeitung und Anwendung 

6.1 Surface treatment 

processes 

Prozesse für die 

Oberflächenbehandlung 

Henkel AG & Co. KGaA 

D-40191 Düsseldorf 

Tel. +49 (0) 211 / 797-30 00 

Fax +49 (0) 211 / 798-23 23 

Internet: www.henkel-technologies.com 

� Adhesive bonding / Verkleben 


siehe Prozesse für die Oberflächentechnik 6.1 

� Anodising / Anodisation 



� Joining / Fügen 



� Cleaning / Reinigung 



� Pretreatment before coating 

Vorbehandlung vor der Beschichtung 




6.2 Semi products 

Halbzeuge 

� Wires / Drähte 

DRAHTWERK ELISENTAL 

W. Erdmann GmbH & Co. 

Werdohler Str. 40, D-58809 Neuenrade 

Postfach 12 60, D-58804 Neuenrade 

Tel. +49(0)2392/697-0, Fax 49(0)2392/62044 

E-Mail: info@elisental.de 

Internet: www.elisental.de 


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87. Jahrgang 1.1.2011 

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Giesel Verlag GmbH 

Post fach 5420, 30054 Hannover 

Hans-Böckler-Allee 9, 30173 Hannover 

Tel. 0511 7304-0, Fax 0511 7304-157 

giesel@giesel.de, www.giesel-verlag.de 

Postbank / postal cheque account Hannover, 

BLZ / routing code: 25010030; Kto.-Nr. / 

account no. 90898-306, Bankkonto/bank account 

Commerzbank AG, BLZ/routing code: 25040066, 

Kto.-Nr./account no. 1500222 

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Klaus Krause 

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Dipl.-Vw. Volker Karow. 

Chefredakteur, Editor in Chief 

Franz-Meyers-Str. 16, 53340 Meckenheim 

Tel. +49(0)2225 8359643 

Fax +49(0)2225 18458 

vkarow@online.de 

Dipl.-Ing. Rudolf P. Pawlek 

Hüttenindustrie und Recycling 

rudolf.pawlek@span.ch 

Dipl.-Ing. Bernhard Rieth 

Walzwerkstechnik und Bandverarbeitung 

rollingmill-technology@t-online.de 

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Dennis Roß 

Tel. 0821 319880-34, d.ross@giesel.de 

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Tel. 0511 7304-148, b.schaefer@giesel.de 

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Preisliste Nr. 51 vom 1.1.2011. 

Price list No. 51 from 1.1.2011. 

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Jutta Illhardt 

Tel. 0511 7304-126, j.illhardt@giesel.de 

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Sabrina Matzat 

Tel. 0511 7304-125, vertrieb@giesel.de 

6.3 Equipment for forging 

and impact extrusion 

Ausrüstung für Schmiedeund 

Fließpresstechnik 

� Hydraulic Presses 

Hydraulische Pressen 

LASCO Umformtechnik GmbH 

Hahnweg 139, D-96450 Coburg 

Tel. +49 (0) 9561 642-0 

Fax +49 (0) 9561 642-333 

E-Mail: lasco@lasco.de 

Internet: www.lasco.com 

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EUR 289,- (Inland inkl. 7% MwSt. und Versandkosten). 

Europa EUR 289,- inkl. Versandkosten. 

Einzelausgabe EUR 28,90. Übersee US$ 382,- inkl. 

Normalpost; Luftpost zzgl. US$ 82,-. Einzelausgabe 

US$ 38,20. Preise für Studenten auf Anfrage. ALU- 

MINIUM erscheint zehnmal pro Jahr. Kündigungen 

jeweils sechs Wochen zum Ende der Bezugszeit. 

�� 

EUR 289.00 p.a. (domestic incl. V.A.T.) plus postage. 

Europe EUR 289.00 incl. surface mail. Single 

copy EUR 28,90. Out side Europe US$ 382.00 incl. 

surface mail, air mail plus US$ 82.00. Single copy 

US$ 38,20. ALUMINIUM is published monthly (10 

issues a year). Cancellations six weeks prior to the 

end of a year. 

Die Zeitschrift und alle in ihr enthaltenen Beiträge 

und Abbildungen sind urheberrechtlich geschützt. 

Jede Verwertung außerhalb der en gen Grenzen 

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in elektronischen Systemen. Der Verlag 

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nicht für abgeleitete Folgen. Haftung bei Leistungsminderung 

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ISSN: 0002-6689 

© Giesel Verlag GmbH 

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Büro Augsburg: 

Gögginger Straße 105a, 86199 Augsburg 

Dennis Roß 


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Tel. 0821 319880-37, c.mayer@giesel.de 

Stephan Knauer 

Tel. 0821 319880-19, s.knauer@giesel.de 

Fax 0821 319880-80 


8 Literature 

Literatur 

� Technical literature 

Fachliteratur 

Taschenbuch des Metallhandels 

Fundamentals of Extrusion Technology 


Hans-Böckler-Allee 9, 30173 Hannover 

Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233 

Internet: www.alu-bookshop.de 

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Büro Augsburg: 

Gögginger Straße 105a, 86199 Augsburg 

Dennis Roß 


Claus Mayer 

Tel. 0821 319880-37, c.mayer@giesel.de 

Stephan Knauer 

Tel. 0821 319880-19, s.knauer@giesel.de 

Fax 0821 319880-80 

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JORDI PUBLIPRESS 

Postfach 154, CH-3427 Utzenstorf 

Tel. +41(0)32 6663090 

Fax +41(0)32 6663099 

info@jordipublipress.ch, www.jordipublipress.ch 

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Verlagsbüro Michaela Wotawa 

Sonnenweg 83, A-1140 Wien 

Tel. +43(0)699 10455027 

m.wotawa@aon.at 

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MEDIAPOINT & COMMUNICATIONS SRL 

Corte Lambruschini – Corso Buenos Aires, 8 

V o piano – Interno 7, I-16129 Genova 

Tel. +39(0)10 5704948, 

Fax +39(0)10 5530088 

info@mediapointsrl.it, www.mediapointsrl.it 

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Marketing Xpertise Rieth 

Dipl.-Ing. Bernhard Rieth 

Strümper Berg 10, D-40670 Meerbusch 

Tel. +49(0)2159 962643 

Fax +49(0)2159 962644 

marketing.xpertise@t-online.de 

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DEF & Communication 

Nicolas Boncoeur 

48 boulevard Jean Jaurès 

F-92110 Clichy 

Tel. +33(0)147307180, Fax +33(0)147300189 

nboncoeur@defcommunication.com 

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Gutenberg Beuys Feindruckerei GmbH 

Große Düwelstraße 20, 30171 Hannover 


VORSCHAU / PREVIEW 

IM NÄCHSTEN HEFT 

Special: die Aluminiumhüttenindustrie 

Wir berichten über Unternehmen und Ausrüster der internationalen 

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und innovative Entwicklungen. Beiträge unter anderem: 

• Unternehmensporträt Innovatherm – Spezialist für 

Feuerungssysteme von Anodenbrennöfen und 

Rauchgasreinigungsanlagen für die Aluminiumindustrie 

• Interview mit Mahmood Daylami, Generalsekretär des 

Gulf Aluminium Council 

Weitere Themen 

• 100 Jahre Strangpressen bei Erbslöh 

• Aluminium im Flugzeugbau – 

alles andere als ein Auslaufmodell 

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IN THE NEXT ISSUE 

Special: the aluminium smelting industry 

We will report on companies and equipment partners of the 

international aluminium smelting industry: on new orders, 

projects and technological developments. 

• Company profile of Innovatherm – specialist for 

advanced firing systems for anode baking furnaces and 

fume treatment plants for the aluminium industry 

• Interview with Mahmood Daylami, general secretary of 

the Gulf Aluminium Council 

Further topics 

• 100 years of extrusion at Erbslöh 

• Aluminium in aircraft construction – 

far from being a discontinued model 

Datum / date Unterschrift/Signature 

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