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Vollert 

Vollert 

OffIcIAL OffIcIAL INterNAtIONAL 

INterNAtIONAL 

MedIA MedIA PArtNer 

PArtNer 

Special: Special: Aluminium 

Aluminium 

2010 2010 – – Fair Fair preview 

preview 

SMS SMS Siemag Siemag – – Convincing 

Convincing 

added added value value from from integraintegrativetive 

rolling rolling plant plant solutions 

solutions 

Improved Improved cylinder 

cylinder 

lining lining coating coating reduces 

reduces 

friction friction and and weight 

weight 

Treatment Treatment of of cover cover matematerialrial 

from from electrolysis electrolysis pots 

pots 

7/8 

7/8 

Volume Volume 86 86 · · July July / / August August 2010 

2010 

International International Journal Journal for for Industry, Industry, Research Research and and Application 

Application

Linear inspection system. Helical inspection system. 

Ultrasonic inspection systems 

State-of-the-art non destructive testing 

Leading technology in the aluminum casthouse. 

There are many benefits in one-stop-shopping 

of industrial goods. At Hertwich Engineering we 

provide customer oriented service throughout 

the project duration and service life of equipment. 

We design and build plants to meet both, our 

own stringent standards and individual customers 

speci fications. Based on many years of experience, 

we cover the full range of equipment in a modern 

aluminum casthouse. 

Major benefits 

Hertwich Engineering is well-known for leading 

edge technology. Our valued customers deserve 

to get the best value for money. 

Commitment to innovation, solid engineering and 

own R&D are instrumental for staying ahead with 

continuous improvements and new products. 

HERTWICH ENGINEERING GMBH 

Weinbergerstrasse 6 

5280 Braunau, Austria 

Phone: +43 (0) 7722 806-0 

Fax: +43 (0) 7722 806-122 

Ultrasonic inspection systems 

Linear testing for center crack detection 

Helical testing for full inspection of metal volume 

Designed to fulfil ASTM B594 

Inspection of billets to Class A, as required for 

automotive and aerospace industries 

Angle beam technique for inclusion and surface 

fault detection 

Faulty logs can be tracked back up to the corresponding 

mould of the casting station 

Statistical data analysis for helping to pinpoint 

reasons for defects, contributing to minimize 

scrap at the source 

E-mail: info@hertwich.com 

Internet: www.hertwich.com 

Visit us at 

ALUMINIUM 2010 

Hall 3, Booth No. 3A40 

September 14 to 16 

Essen, Germany 

MEETING your EXPECTATIONS

Volker Karow 

Chefredakteur 

Editor in Chief 

Vergünstigung oder 

Nachteilsausgleich? 

Concession or 

compensation for 

disadvantage? 

ALUMINIUM · 7-8/2010 

Angesichts hoher Staatsschulden 

prüfen die Regierungen, vor allem 

die in Europa, derzeit fieberhaft, wo 

Ausgaben gekürzt und neue Einnahmequellen 

aufgetan werden können. 

In Deutschland wird seit Monaten 

unter anderem darüber diskutiert, 

wie Windfall Profits aus einer Laufzeitverlängerung 

von Kernkraftwerken 

wenigstens zum Teil abgeschöpft 

werden können. Einen staatlich garantierten 

Jackpot wie seinerzeit bei 

der kostenlosen Zuteilung von Emissionszertifikaten 

an die Stromkonzerne 

soll es nicht noch einmal geben. 

Gut so, möchte man rufen. 

Damit nicht genug scheint die 

Bundesregierung aber auch die 

Stromsteuern für Unternehmen des 

produzierenden Gewerbes in den 

Blick zu nehmen – ursprünglich, um 

Mitnahmeeffekte bei Energiesteuervergünstigungen 

zu vermeiden. Dagegen 

wäre ja nichts einzuwenden, doch 

zeichnet sich inzwischen ab, dass es 

nicht dabei bleiben soll, Trittbrettfahrern 

die Tour zu vermasseln. Es geht 

um höhere Energiesteuern, die die 

energieintensiven Unternehmen und 

damit wichtige Industriezweige am 

Standort Deutschland gefährden. 

Der BDIChef Werner Schnappauf 

hat zu Recht darauf hingewiesen, 

dass der Begriff „Vergünstigungen“ 

irreführend ist. Bei den ermäßigten 

Energiesteuersätzen und dem Spitzenausgleich 

bei der Ökosteuer handelt 

es sich nicht um die Gewährung von 

Vorteilen, sondern um den Ausgleich 

von Wettbewerbsnachteilen gegenüber 

anderen Standorten. In anderen 

Ländern gibt es diese Steuern nicht 

oder nicht in vergleichbarer Höhe. 

Eine Kürzung dieses Ausgleichs 

würde mithin die im internationalen 

Wettbewerb stehende Industrie belasten 

und Wachstum und Arbeitsplätze 

gefährden. 

Sie würde auch die Grundlagen 

für einen erfolgreichen Klimaschutz 

untergraben. Denn gerade klassische 

Industrien mit ihren Technologien 

sind es, die Windparks, leichte Automobilkarosserien, 

LithiumIonen 

Akkus oder DünnschichtSolarzellen 

möglich machen. Sie bilden die Basis 

für zukunftsfähige Produkte, mit denen 

Deutschland auch künftig seinen 

Wohlstand sichern kann. 

e d i t o r i a l 

Given the high levels of national debt, 

governments, and especially those in 

Europe, are currently frantically looking 

for ways to cut expenditure and 

open up new sources of income. In 

Germany, one of the topics that has 

been under discussion for months is 

how to skim off, at least in part, windfall 

profits resulting from extending 

the permitted operating life of nuclear 

power stations. There will be no stateguaranteed 

jackpot again this time like 

there was when emission certificates 

were distributed free of charge to the 

power companies. “That’s good”, one 

would like to cry. 

As if that was not enough, the 

German Federal Government now 

appears to also have its eye on the 

electricity tax for companies involved 

in manufacturing – initially in order 

to avoid windfall gains from energytax 

concessions. One could not argue 

against that but in the meantime there 

are indications that the matter is not 

going to rest at spoiling things for 

those jumping on the bandwagon. It is 

about higher energy taxes that will put 

the energyintensive companies and 

thus important branches of industry 

at risk, and with it Germany’s position 

as a location for investment and 

industrial production. 

The director general of the Federation 

of German Industries, Werner 

Schnappauf, has rightly pointed out 

that the term ‘concession’ is misleading. 

The reduced rates of energy tax 

and the compensation for peak levels 

of ecotax are not concessions but the 

offsetting of competitive disadvantages 

in Germany compared with other 

locations. These taxes do not exist 

in other countries, or at least not to 

a comparable extent. Reducing this 

compensation would thus put pressure 

on industries that face international 

competition and jeopardise 

growth and jobs. 

Indeed, it would undermine the basis 

for successful climate change prevention. 

Because it is precisely these 

industries and their technologies that 

make wind parks, lightweight car 

bodies, lithiumion batteries or thinfilm 

solar cells possible. They provide 

the basis for the sustainable products 

with which Germany can also maintain 

its prosperity in future.

i N H a l t 

14 

18 

28 

8 

Der ALUMINIUM-Branchentreff 

des Giesel Verlags: www.alu-web.de 


Vergünstigung oder Nachteilsausgleich? .................................... 

a Kt U e l l e S 

Unternehmen, Märkte, Personen ............................................ 6 

Automotive Forum: Leichtbau mit CFKs bleibt eine Herausforderung 10 

W i r t S C H a F t 

Englischsprachige Artikel: s. nebenstehendes Verzeichnis 

Produktionsdaten der deutschen Aluminiumindustrie .................. 11 

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

a l U M i N i U M 2 0 10 – V o r S C H a U 

Der Countdown läuft – ALUMINIUM 2010 wirft ihr Licht voraus ..... 18 

Führende Aluminiumkonzerne fördern 

den European Aluminium Award 2010 .................................... 2 

ALUMINIUM China 2010 signalisiert 

großes Potenzial im asiatischen Markt .................................... 26 

t e C H N o lo G i e 

Englischsprachige Artikel: s. nebenstehendes Verzeichnis 

SMS Siemag: Überzeugender Mehrwert 

durch integrative Walzwerklösungen ...................................... 28 

Erdbebensicheres Hochregallager: Aberle Automation realisiert 

innovatives Steuerungskonzept für chinesisches Folienwalzwerk ..... 4 

Weiterentwickelte Laufbahnbeschichtung 

reduziert Reibung und Gewicht ............................................ 6 

Ein Ansatz zur Steigerung der Stromausbeute: 

Aufbereitung von Abdeckmaterial aus Elektrolysezellen ............... 8 

Maßgeschneiderte Lösungen zur 

Energie- und Datenübertragung in Aluminiumhütten .................. 41 

i N t e r N at i o N a l e B r a N C H e N N e W S ................... 51 

d o K U M e N tat i o N 

Patente ......................................................................... 61 

Impressum ..................................................................... 81 

Vorschau........................................................................ 82 

B e Z U G S Q U e l l e N V e r Z e i C H N i S ............................ 65 

4 ALUMINIUM · 7-8/2010


Concession or compensation for disadvantage? ........................... 

N e W S i N B r i e F 

Companies, markets, people .................................................. 7 

e C o N o M i C S 

Talum d.d. Kidricevo – Slovenia’s exemplary smelter ................... 14 

a l U M i N i U M 2 0 10 – P r e V i e W 

The countdown is running – ALUMINIUM 2010 on the horizon ..... 18 

Leading aluminium players sponsor 

European Aluminium Award 2010 ......................................... 2 

ALUMINIUM China 2010 signals promising opportunities in Asia .... 26 

t e C H N o lo G Y 

SMS Siemag: Convincing added value 

from integrative rolling plant solutions ................................... 28 

Luoyang Longding Alu orders process automation systems 

for aluminium rolling lines from Siemens ................................. 5 

Improved cylinder lining coating reduces friction and weight ........ 6 

An approach toward increasing current yield: 

Treatment of cover material from electrolysis pots ..................... 8 

Tailor-made solutions for energy and data 

transmission in aluminium smelters ....................................... 41 

EMC confirms its quality lead: 

Increase in capacity at Amag casting in Ranshofen ..................... 44 

Production planning in the aluminium recycling industry 

made easy with an add-on to SAP ERP ................................... 48 

C o M Pa N Y N e W S W o r l d W i d e 

Aluminium smelting industry ............................................... 51 

Bauxite and alumina activities .............................................. 51 

Recycling and secondary smelting ......................................... 52 

Aluminium semis .............................................................. 5 

On the move................................................................... 54 

Suppliers........................................................................ 55 

r e S e a r C H 

A corrosion study of brazed aluminium 

heat exchangers after field service ......................................... 56 

d o C U M e N tat i o N 

Imprint .......................................................................... 81 

Preview ......................................................................... 82 

S o U r C e o F S U P P lY l i S t i N G ............................... 65 


inserenten 

dieser ausgabe 

list of advertisers 

C o N t e N t S 

41 

44 

ABB Schweiz AG, Switzerland 13 

Achenbach Buschhütten GmbH 19 

Aleris Aluminium Koblenz GmbH 21 

Alu Menziken Extrusion AG, Switzerland 8 

Coiltec Maschinenvertriebs GmbH 53 

Drache Umwelttechnik GmbH 37 

Ebner-Industrieofenbau 

Gesellschaft m.b.H., Austria 50/51 

GDA Gesamtverband der 

Aluminiumindustrie e.V. 23 

Hertwich Engineering GmbH, Austria 2 

Inotherm Industrieofen- 

und Wärmetechnik GmbH 6 

IST Industrieofen + Stranggieß-Technik GmbH 24 

LOI Thermprocess GmbH 6 

Micro-Epsilon Messtechnik GmbH & Co. KG 25 

Oilgear Towler GmbH 20 

Precimeter Control AB, Sweden 9 

Schwartz GmbH 35 

Seco/Warwick S.A., Poland 17 

SMS Siemag Aktiengesellschaft 84 

Wagstaff Inc., USA 15 

Wirtschaftsvereinigung Metalle e.V. 27 

5

A K T u e l l e s 

erhöhung der stromsteuer für industrie setzt falsche Zeichen 

Der Bundesrechnungshof schlägt vor, 

die Entlastung von Unternehmen bei 

der Stromsteuer von 95 auf 50 Prozent 

zu reduzieren. Für einen Groß - 

teil des produzierenden Gewerbes 

würde dies eine Verzehnfachung der 

Stromsteuerbelastung bedeuten. Statt 

Anzeige 

0,615 Euro je MWh wären dann 6,15 

Euro je MWh zusätzlich zum aktuellen 

Strompreis von rund 50 Euro je 

MWh zu zahlen. Für viele Unternehmen 

hätte dies jährliche Mehrbelastungen 

in Millionenhöhe zur Folge. 

Martin Kneer, Hauptgeschäftsführer 

der Wirtschaftsvereinigung Metalle 

(WVM), kritisiert derartige Überlegungen. 

Es sei unverständlich, wenn 

die Bundesregierung einerseits Kom- 

�� 

�� 

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pensationen für die energieintensive 

Industrie beschließe und andererseits 

über Belastungen eben dieser Unternehmen 

nachgedacht werde. Die bisherige 

Entlastung der Energiesteuern 

auf 50 Prozent zu reduzieren erscheine 

willkürlich und gefährde die 

Konjunktur und den Arbeitsmarkt. 

Die WVM begrüßt das Ziel der 

Bundesregierung, Mitnahmeeffekte 

aus Steuervergünstigungen für Unternehmen 

außerhalb des produzierenden 

Gewerbes, die nicht energieintensiv 

sind und nicht im internationalen 

Wettbewerb stehen, zu streichen. 

Die angestrebte Streichung von 

bis zu 1,5 Milliarden Euro erfasse 

jedoch auch energieintensive Unternehmen. 

Kneer verweist darauf, dass 

die Ökosteuer 1999 mit dem Ziel 

eingeführt wurde, die Sozialversicherungsbeiträge 

zu senken. „Damit es 

gerade für energieintensive Unternehmen 

nicht zu einer Mehrbelastung, 

sondern zur beabsichtigten 

Entlastung kam, wurde der Spitzen- 

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ausgleich eingeführt“, so Kneer. 

Der Spitzenausgleich ist direkt an 

die Einhaltung der Klimaschutzvereinbarung 

der deutschen Industrie 

mit der Bundesregierung geknüpft. 

Das Ziel für 2012, die spezifischen 

Treibhausgasemissionen um 35 Prozent 

gegenüber dem Referenzjahr 

1990 zu reduzieren, wurde 2008 bereits 

zu über 100 Prozent erfüllt. 

Das Ausmaß der drohenden Belastung 

zeigen folgende Beispiele des 

VIK. Bei einem jährlichen Strombedarf 

von 10 Gigawattstunden (GWh), wie 

er für einen relativ kleinen Betrieb der 

Metallverarbeitung typisch ist, stiege 

nach den Vorschlägen des Bundesrechnungshofes 

die Ökosteuerbelastung 

von etwa 6.000 auf 60.000 Euro 

im Jahr. Ein mittelständisches Unternehmen 

mit einem Strombedarf von 

100 GWh hätte mit Mehrkosten von 

500.000 Euro zu rechnen. Große und 

stromintensive Unternehmen (1.000 

GWh) träfen Zusatzbelastungen von 

mehreren Millionen Euro im Jahr. 

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6 ALUMINIUM ·7-8/2010

The Saudi Arabian Mining Company 

Ma’aden and US aluminium giant 

Alcoa officially broke ground on 19 

June on a project that will become 

the world’s largest fully integrated 

aluminium complex, at Ras az Zawr 

in Saudi Arabia. Ken Wisnoski, president 

Alcoa Global Primary Products, 

pointed to the progress that has been 

made since the joint venture was 

formed. “In the near future, the place 

where we stand today will become 

the regional hub of the Kingdom’s 

new aluminium industry, and home 

of the Middle East’s first, and one of 

the world’s most technologically advanced, 

food-grade can sheet rolling 

mills”, he said. 

In December 2009 the two companies 

announced their joint venture to 


develop a fully integrated aluminium 

complex in the Kingdom of Saudi 

Arabia, consisting of a bauxite mine 

at Al Ba’aitha and an alumina refinery, 

aluminium smelter and rolling 

mill on the Arabian Gulf coast at Ras 

Az Zawr. Ground breaking has now 

officially begun to pave the way for 

construction of the smelter and rolling 

mill that will serve the packaging 

and other industries. 

The joint venture is supposed to 

become the world’s preeminent and 

lowest-cost supplier of primary aluminium 

and aluminium products, 

with access to the growing markets of 

the Middle East and beyond. The complex 

will utilise critical infrastructure, 

including low-cost and clean power 

generation as well as port and rail fa- 

N e w s i N b r i e f 

Ma’aden-Alcoa joint venture breaks ground in saudi Arabia 

sapa expands in south-east Asia 

Sapa intends to enter a joint venture 

with the Vietnamese Ben Thanh group 

by acquiring 65 percent of the shares 

of the aluminium extrusion company 

Vijalco (Vietnam Japan Aluminium 

Co.). Sapa sees the opportunity to develop 

Vijalco to a major player in the 

Vietnamese market and support the 

Swedish company in its strategy of establishing 

a broader footprint in Asia. 

The total value of the deal, including 

investments to upgrade equipment, 

investments in new production capacity 

and extending land leases, is 

about 100 MSEK. 

Vijalco is a joint venture between 

the Japanese companies Tachibana 

and Sojitz Corp. and the Vietnamese 

Ben Thanh group, established in 1996. 

Vijalco is located in Ho Chi Min City. 

The current production capacity 

is small (about 5,000 t), but still the 

company has established a strong position 

in selected segments of the Vietnamese 

market. Its operations include 

one press, an anodising line and some 

fabrication activities. The production 

covers both standard profiles to the 

building and construction sector and 

more specialised solutions for the furniture 

and automotive industries. The 

company employs 150 people. 

Sapa 

“It is Sapa’s clear ambition to grow in 

Asia and we are currently working on 

a number of projects to achieve this. 

Sapa’s original plan was to enter Vietnam 

at a later stage; however, we 

were given a chance to join forces 

Profiles from Sapa, one of the global market 

leaders in the extrusion sector 

with a strong local partner and access 

a rapidly growing economy. The 

acquisition of Vijalco thus only marks 

a first step for further progress in the 

region”, says Björn Wiggen, Sapa’s 

president and CEO. 

cilities developed by the Kingdom’s 

government. Bauxite feedstock for 

the planned alumina refinery will be 

transported by rail from the new mine 

at Al Ba’itha, near Quiba, in the north. 

The smelter and rolling mill will begin 

operations in 2013 with the mine and 

refinery coming on stream in 2014. 

Ras Az Zawr is the location for 

Ma’aden’s minerals industry complex, 

a 77 square km site, 90 km north of 

Al Jubail on the Arabian Gulf coast of 

Saudi Arabia. In addition to housing 

the aluminium complex, it is the site 

for Ma’aden Phosphate Company’s integrated 

chemical and fertilizer facility, 

due to begin operation in 2010. 

Alcoa Europe is an exhibitor at 

ALUMINIUM 2010. Hall 3, Stand 

B50. 

Sapa intends to acquire 65 percent 

of the shares in Vijalco by purchasing 

the Japanese parties’ shares and 

by participating in a planned capital 

increase. The transaction needs to be 

approved by the respective companies’ 

boards as well as the Vietnamese 

authorities; it is expected to be closed 

during the third quarter of 2010. 

seK80m investment in sapa 

Heat Transfer in finspång 

Safety and increased capacity is the 

focus of an SEK80 million investment 

in Sapa Heat Transfer in Finspång, 

Sweden. As research and development 

are vital to competitiveness in 

the automotive industry, Sapa Heat 

Transfer has decided to invest in an 

application centre, where the company 

can develop the materials and 

applications of the future. 

Sapa’s three cold rolling mills will 

also be upgraded. In addition, the handling 

of material in and around the 

plant will be improved, and the works 

will be modified to ensure that they 

can cope with faster rolling speeds. 

Sapa Profiles Europe is an exhibitor 

at ALUMINIUM 2010. Galeria 

G05.

A K T u e l l e s 

Neuer firmenname: 

Gutmann AG 

Die Hermann Gutmann Werke heißen 

jetzt Gutmann AG. Hintergrund ist, dass 

der Name Gutmann im internationalen 

Geschäftsverkehr einprägsamer ist. Vor 

über sieben Jahrzehnten als Leichtmetall-Drahtwerk 

im fränkischen Weißenburg 

gegründet, hat sich Gutmann 

längst zu einer weltweit agierenden 

Unternehmensgruppe entwickelt. Dazu 

zählen die Firmen Gutmann, Gartner 

Extrusion, NordAlu und Gutmann Aluminium 

Draht. Die Gutmann-Gruppe 

gehört zur griechischen Alco-Gruppe, 

Muttergesellschaft ist die börsennotierte 

Alco Hellas S.A., Athen. An verschiedenen 

Standorten werden hochwertige 

Aluminiumprodukte hergestellt. 

• Strangpressen 

Gutmann ist Aussteller auf 

der ALUMINIUM 2010. Halle 

3, Stand M30. 

• Oberflächenveredelung 

• Mechanische Bearbeitung 

• Engineering 

• Bolzengiessen 

• Baugruppenfertigung 

• Logistik 

• Recycling 

Alu Menziken Extrusion AG 

Hauptstrasse 35 

CH-5737 Menziken 

Telefon +41 62 765 22 37 

Telefax +41 62 765 22 39 

extrusion@alu-menziken.com 

A Company of Montana Tech Components AG 

schüco gewinnt Marktanteile 

Der Systemhersteller für Fenster, 

Türen, Fassaden sowie Solartechnik, 

Schüco International, erzielte im vergangenen 

Geschäftsjahr einen Umsatz 

von fast zwei Milliarden Euro 

(2008: 2,15 Mrd. €). Das Unternehmen 

konnte eigenen Angaben zufolge 

seine Marktanteile in Deutschland, 

aber auch in wichtigen europäischen 

Märkten ausweiten. 

Der Ausbau der Solardivision mit 

einer nahezu 30-prozentigen Mengensteigerung 

setzte sich ungebremst 

fort, der Umsatz dieses Geschäftsfeldes 

erhöhte sich jedoch aufgrund 

der geringeren Fördersätze aus dem 

Erneuerbare-Energien-Gesetz (EEG) 

nicht. Die Metallbau- und Kunststoffsparte 

profitierten insbesondere vom 

Konjunkturpaket II in Deutschland. 

Der zum Teil dramatische Einbruch 

der Baumärkte in Russland, USA, 

Aluminium in Bestform 

�� 

England und Spanien trugen ebenfalls 

zum Rückgang der Umsätze bei. Das 

Ergebnis der Geschäftstätigkeit war 

zufriedenstellend. Die Eigenkapitalquote 

wuchs auf 58,7 Prozent (2008: 

56,4%). 

Trotz des harten Winters in Mitteleuropa 

gelang Schüco eigenen Anga- 

Schüco ist Aussteller auf der ALU 

MINIUM 2010. Hall 1, Stand G24. 

ben zufolge ein sehr guter Start in das 

laufende Geschäftsjahr. Das gilt insbesondere 

für den deutschen Markt. 

Solar konnte seinen Umsatz gegenüber 

dem Vorjahreszeitraum mehr 

als verdoppeln, da die Reduzierung 

der Einspeisevergütungen zum 01. 

Juli zu Vorzieheffekten führte. Dies 

dürfte jedoch im zweiten Halbjahr 

eher Bremsspuren hinterlassen. 

Henkel und bAsf 

Coatings kooperien 

Die Firmen Henkel und BASF Coatings gründen 

ein Joint Venture, um innovative Korrosionsschutzlösungen 

für die Automobilindustrie 

zu entwickeln. Beide Partner werden 

sich je zur Hälfte an der neuen Gesellschaft 

mit Sitz in Düsseldorf beteiligen, die Anfang 

2011 ihre Arbeit aufnehmen soll. Das Joint 

Venture bedarf noch der kartellrechtlichen 

Zustimmung. 

Die neue Gesellschaft ist zunächst auf 

Forschung und Entwicklung ausgerichtet. 

Sie soll die spezifischen Kompetenzen beider 

Partner in den Bereichen Metallvorbehandlung 

und Tauchlackierung mit dem Ziel 

zusammenführen, Produkte und Verfahren 

zu entwickeln, die wirtschaftlicher, leistungsfähiger 

und umweltverträglicher sind 

als die heutigen Standardprozesse zum Korrosionsschutz 

in der Automobilindustrie. 

Insbesondere eine Verringerung der Prozessschritte 

für Metallvorbehandlung und 

Korrosionsschutz würde Kunden für die 

erste Phase der Automobillackierung umfassende 

Vorteile bieten, heißt es bei Henkel. 

Beide Partner werden ihr bisheriges Produktportfolio 

weiterhin getrennt vermarkten. 

Henkel ist Aussteller auf der ALU 

MINIUM 2010. Hall 2, Stand D42. 


Hydro to build recycling plant in Norway 

Hydro will build Norway’s largest 

plant for aluminium recycling at 

Karmøy. The plant will have an initial 

capacity of 35,000 tonnes. The total 

investment will be about NOK260 

million (€32m) and establish close to 

40 new jobs in the plant. In Norway 

Hydro has been recycling aluminium 

only in Holmestrand. 

Final build decision is planned for 

the spring of 2011. The new recycling 

facility is to start operation in summer 

2012. It will then be in position 

to take in and recycle dross and scrap 

from all of Hydro’s aluminium plants 

in Norway. Dross is a residue from the 

Novelis has announced that it will 

invest approx. USD300 million to expand 

its aluminium rolling operations 

in Pindamonhangaba, Brazil. The 

expansion will increase the plant’s 

capacity by more than 50% to over 

600,000 tonnes of aluminium sheet 

per year. The project, which includes 

a third cold rolling mill, a new ingot 

casting centre, a new pusher furnace 

for the hot rolling mill and various 

ancillary improvements, is expected 

to come on stream in late 2012. It is 

the largest single capital investment 

Novelis has made since the company 

was launched five years ago. 

“We are experiencing strong demand 

for our products in South 

America, particularly for beverage 

can sheet”, said Phil Martens, presi- 

dent and chief operating officer of 

Novelis. “Growing per capita income 

and changes in consumer behaviour 

are driving double-digit growth in demand 

for beverage cans. Many of our 

South American customers are accelerating 

their investments in can making 

plants and our expansion at Pindamonhangaba 

will allow us to stay 

ahead of that demand”, he added. 

According to Abralatas (Brazilian 

Association of Highly Recyclable 


casting process, with high aluminium 

content. In addition the plant will 

be able to recycle aluminium from 

external sources in Scandinavia and 

Iceland. 

The recycled metal will be utilised 

by Hydro’s product casthouse 

at Karmøy and will partly offset the 

previous Søderberg potlines that were 

closed in March 2009. The construction 

work will start when the demolition 

of the closed Søderberg lines has 

freed up the area to be used for the 

recycling plant. 

First stage in the construction will 

include one tilting rotating furnace 

Novelis expands its rolling operations in brazil 

Novelis is an exhibitor at ALU 

MINIUM 2010. Hall 3, Stand E20. 

Cans Manufacturers), can sales in 

Brazil grew by 11.7% in 2009, representing 

a consumption of 14.8 billion 

units or 40.5 million aluminium cans 

per day. 

Novelis is the leading producer 

of flat rolled aluminium 

products 

in South America. 

The Pindamonhangaba 

facility is 

an integrated hot 

rolling, cold rolling 

and recycling 

complex located 

in the state of Sao 

Paulo. The company 

also operates 

a foil mill at Santo 

Andre, Brazil, two 

aluminium smelters 

at Ouro Preto 

and Aratu, and 

nine hydroelectric 

plants located 

throughout the 

state of Minas Gerais. 

The aluminium 

can is also a recycling 

success story 

in Brazil where 

the recycling rate 

is currently estimated 

at better 

than 91%, placing 

N e w s i N b r i e f 

with a capacity of 35,000 tonnes 

as well as all buildings, filter plant 

and infrastructure. The stage also 

encompasses equipment for liquid 

metal transportation into the product 

casthouse as well as for casting into 

sows. 

Stage two, planned to start when 

the first furnace is running at full capacity, 

will include a second furnace 

with a capacity of another 35,000 

tonnes. 

Norsk Hydro is an exhibitor at 

ALUMINIUM 2010. Hall 3, Stand 

A20. 

the country among the world leaders 

in beverage can recycling. Novelis is 

South America’s largest recycler of 

cans, processing about eight billion 

cans in 2009, providing both economic 

and environmental benefits. 

SENSOREN, STELLANTRIEBE & SYSTEME 

- für die Kontrolle von flüssigen Metallen 

Die Einführung der Precimeter 

Technologie hat viele Vorteile 

• Verbesserung der Qualität 

• Produktivitätssteigerung 

• Dokumentation des Prozesses 

• Einsparung von Rohstoffen 

• Energieeinsparungen 

• Verbesserter Personaleinsatz 

www.precimeter.com 

info@precimeter.com 

9

Foto: Audi 

Erstes CCeV Automotive Forum in Neckarsulm 

Leichtbau mit CFKs bleibt eine Herausforderung 

Am 24. Juni dieses Jahres fand im 

Audi Forum in Neckarsulm das 

erste „CCeV Automotive Forum“ 

statt. Rund 250 Fachbesucher 

nutzten die Gelegenheit, um sich 

aus erster Hand über den Fortschritt 

des Leichtbaus mit CFK 

zu informieren und sich in Gesprächen 

mit Kollegen aus anderen 

Unternehmen oder Instituten 

auszutauschen. 

Aus nahezu allen Reden, die auf der 

Veranstaltung gehalten wurden, ging 

hervor: So überzeugend CFKs als extrem 

leichtes, festes und steifes Material 

sind, so groß sind nach wie vor 

die Hemmnisse für ihren breiten Einsatz 

in der Großserie. Dazu müssen 

die Kosten für Carbonfaser-Bauteile 

deutlich sinken und die Taktzeiten 

drastisch geringer werden. Aber: Bei 

der Manufaktur des Audi R8, beim 

Porsche Carrera GT oder auch bei 

Nutzfahrzeugen werden schon heute 

Faserverbundwerkstoffe eingesetzt. 

Dabei zeigt sich, dass immer dann, 

wenn der Preis eine geringere Rolle 

spielt und die Stückzahlen niedrig 

sind, die Hemmschwelle für den Einsatz 

von CFKs gering ist. 

Bei Audi setzt man auf die sukzessive 

Steigerung von CFK-Anteilen in 

der Produktion von Premiumfahrzeugen. 

Der Leiter des Audi Leichtbauzentrums 

in Neckarsulm und Gastgeber 

des CCeV Forums, Heinrich 

Timm, plädiert für einen radikalen 

Umschwung im Denken der Automobilbauer: 

„Die Konzepte müssen 

anders werden, wenn wir in Zukunft 

CFK sinnvoll einsetzen wollen.“ Seine 

Kriterien für den serienmäßigen 

Einsatz von CFK-Bauteilen sind die 

Wirtschaftlichkeit, die Produktionstauglichkeit, 

die Fahrfunktionen, die 

CO 2-Bilanz und der Kundennutzen. 

Timm will die Zukunft des Werkstoffs 

Carbon für den Automobilbau ent- 

Audi R8 GT – Heckklappe, Heckstoßfänger und Sideblades 

bestehen aus kohlefaserverstärktem Kunststoff 

des Aufwands bei der Herstellung von 

CFK-Bauteilen muss weg.“ 

Dass es bis dahin noch ein weiter 

und steiniger Weg ist, zeigten die Vorträge 

von Lars Herbeck, Geschäftsführer 

der Voith Materials GmbH, 

und anderen Rednern aus der Praxis. 

„CFK kommt im normalen Auto nicht 

vor“, stellte Herbeck fest, und sieht 

auch für die mittelfristige Zukunft 

keinen Durchbruch auf diesem Gebiet. 

Aber: „Wir glauben daran, dass 

in der Zusammenarbeit von Herstellern, 

Verarbeitern und OEMs der 

nächste Entwicklungsschritt für den 

Großserieneinsatz von CFK liegt.“ 

In diese Richtung ging auch der 

Vortrage von Sebastian Grasser, Benteler-SGL 

Automotive Components. 

Grasser kann sich in drei bis vier 

Jahren die Automatisierung bei der 

Fertigung mit CFK-Bauteilen in der 

Automobilherstellung vorstellen und 

war damit einer der Optimisten in 

der Runde. 

scheidend mitgestalten: „90 Prozent ■ 


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 

% * 

Mai 17,5 -66,8 45,9 -29,7 120,0 -24,6 33,6 -29,1 

Jun 18,2 -64,2 48,8 -28,7 135,8 -17,3 37,5 -30,1 

Jul 19,9 -61,7 51,9 -17,0 149,1 -10,6 40,9 -23,6 

Aug 20,5 -60,4 43,2 -12,5 132,0 -10,4 38,1 -23,1 

Sep 21,2 -57,4 55,7 -10,0 140,9 -10,6 43,4 -16,0 

Okt 24,2 -52,6 55,0 -4,9 143,8 -5,8 45,7 -9,3 

Nov 24,5 -48,1 55,0 14,2 149,1 20,8 45,5 12,6 

Dez 26,1 -41,6 42,4 47,3 109,3 20,5 26,6 14,9 

Jan 10 26,9 -33,6 45,9 14,0 138,4 27,5 37,9 10,3 

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 

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

Primäraluminium 

walzprodukte > 0,2 mm 

w i r T s C H A f T 

sekundäraluminium 

Press- und Ziehprodukte 

11

w i r T s C H A f T 


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e c o n o m i c s 

Talum d.d. Kidričevo – slovenia’s exemplary smelter 

G. Djukanovic, Podgorica 

Bird’s eye view of aluminium smelter Talum 

A long time ago, sometime in 2003, 

the management of Talum, the 

sole Slovenian aluminium smelter, 

announced a new strategy: to decrease 

the production of primary 

aluminium by closing outdated 

technology and to increase the 

production of secondary (recycled 

and remelted) aluminium and 

its alloys. Rapidly rising electricity 

prices in Europe a few years 

later, during the peak of the last 

economic cycle, and in particular 

a sharp drop of the primary 

aluminium price last year proved 

this strategy to be right. Actually, it 

paved the way for the company’s 

survival in tough market conditions, 

when even some bigger 

and stronger market players in 

Europe and around the world had 

to close. 

At the same time, being under state 

control and managed by people who 

have been in this business for over 20 

years, Talum has a ‘softer’ 

working atmosphere 

and more ‘socialist’ 

work conditions compared 

to an average, exclusively 

market-driven 

private company. It is 

an example of a company 

not based on the 

interests of individuals 

or interest groups, but 

on the interests and 

for the benefit of the 

whole country. In that is 

Talum’s main strength 

and importance. Further potential for 

improving Talum’s market position 

consists above all in the diversification 

of sales and purchase contracts 

and customers, as well as a further 

gradual decrease of the workforce. In 

short, it is no exaggeration to claim 

that Talum is not just an aluminium 

producer but an institution motivated 

by devotion and good work. 

General technical characteristics 

and production programme 

Talum commenced production in 

1954 as the first primary aluminium 

producer in the Balkan area. Various 

technologies have been operated 

since then. Currently, only AP18 

technology is used at Talum for electrolysis, 

on what is called Line C, 

since Line A (Søderberg technology 

with 22,000 tpy) and Line B (older 

Pechiney technology with 35,000 tpy) 

were closed permanently in 1991 and 

2007 respectively. Pechiney’s AP18 

technology was introduced in 1988, 

and during the last 22 years Talum 

has been continuously improving the 

performance of its potlines to become 

one of the most efficient smelters in 

the world using this type of technology. 

Average current efficiency is 

95.28%, consumption is 13.166 kWh 

per tonne DC energy and the average 

pot life is more than 3,000 days, using 

best practice techniques and optimisation 

of operational parameters, with 

minimal costs. 

In summer 2002 the second phase 

of modernisation was completed and 

capacity was increased by another 

42,000 tpy (also AP18 technology), 

so the total capacity for primary aluminium 

is 82,000 tpy today. The total 

production capacity of all products, 

including primary, secondary and alloyed 

aluminium is currently around 

130,000 tpy. 

Apart from primary aluminium, 

Talum produces all the main types of 

foundry alloys (over 200) as well as 

extrusion billets, wide strips, evaporators, 

slugs, discs and castings. Its 

strategy for the future is based on the 

remelting of used aluminium scrap. 

The production of secondary aluminium 

already accounts for about 50% 

of total output. The company’s goal is 

to further increase this share. 

Foundry alloys are produced in 

two ways at Talum: continuously-cast 

ingots and mould cast ingots. The production 

of extrusion billets includes 

all standard types with the major alloys: 

6060 alloy AlMgSi0.5; 6005 alloy 

Production structure 

14 ALUMINIUM · 7-8/2010 

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AlMgSi0.7; 6082 alloy AlMgSi1. Billet 

casting is carried out on a semicontinuous 

vertical casting machine 

which uses ‘gas slip’ technology. 

Wide strips (capacity of 8,000 tpy, 

width 1,500 mm, thickness 6 to 10 

mm) are partly used for the fabrication 

of evaporators. Slugs are used for 

the production of aluminium packaging, 

tubes and cans, while discs are 

used as bottoms for stainless steel hollow-ware. 

The capacity for both slugs 

and discs is 22,000 tpy. 

Roll-bond evaporators, another 

product from Talum’s rich production 

programme existing for many 

years, are used as heat exchangers in 

household appliances for cooling and 

freezing purposes. A roll-bond evaporator 

is a compound plate, rolled from 

two aluminium plates, with a channel 

system in between. 

Castings constitute Talum’s newest 

production programme to serve 

the needs of the automotive industry, 

heating and cooling systems and in 

general engineering products. The 

foundry capacity is 3,500 tpy. The 

casting machines are automated using 

PLC process control. The casting 

technology is low-pressure casting (5 

machines) and gravity casting (7 machines). 

The extrusion billet production 

line has a capacity of 65,000 tpy (joint 

venture with Norsk Hydro) and consists 

of two 20-tonne, gas-fired melting 

furnaces, one 40-tonne electric 

resistance holding furnace, two rotor 

Hycast inline HI-45 filters, Hycast gasslip 

casting equipment and a continuous 

homogenising furnace. The rolling 

slab production line has a capacity of 

15,000 tpy and is integrated in the furnace 

system for casting 

strip with a production 

of 8,000 tpy. 

In the casthouse 

there is a two-chamber 

furnace for the remelting 

of aluminium scrap 

and also a new casting 

facility for foundry alloys. 

Talum has its own 

anode plant with a 

capacity of around 

60.000 tpy of prebaked 

anodes. 

Slovenian public electricity supplier 

Eles has an 80% stake in Talum 

which means Talum is still in the 

state’s ownership. Though Eles has 

been considering selling off its stake 

in Talum, there are no plans for privatisation 

at present. It seems that 

the government does not want to lose 

control of one of the country’s leading 

exporters. Glencore International 

offered USD77 million for Talum’s 

80% stake in 2003 but the offer was 

rejected by the government and the 

privatisation tender failed. The remaining 

stakeholders include: Factor 

bank (7.5%), former and present employees 

of Talum (6.6%) and Kapitalska 

družba which is a pension fund 

(5.8%). 

The president of the board and 

chief executive of Talum, Danilo Toplek, 

was re-elected last December for 

another 6-year term. Mr Toplek (57) 

has headed the company for the last 

24 years. 

Production and financial results 

Talum posted €149.6 million in net 

sales revenues for 2009, which is 

48% less than the year before. The 

net loss in 2009 amounted to €6.9 

million. Total revenues in 2008 were 

around €310 million, while net profits 

amounted €358,000. 

Talum has a 7-year sales contract 

with Norwegian Hydro, expiring in 

January 2011, to supply foundry alloy 

products. According to the contract, 

Hydro should receive 70,000 tpy of 

Talum’s foundry alloy and 50,000 

tpy of extrusion billets. This was not 

achieved in 2009 due to production 

curtailments. Hydro has had business 

Sales structure 

relations with Talum since 1987. 

As a consequence of the world 

economic crisis and low aluminium 

prices in 2009, Talum cut its smelter 

production to 35,148 tonnes, or 42% 

of the capacity. Electricity intensity 

was also reduced from 190 kA to 185 

kA. There were 67 out of 160 electrolysis 

pots in operation during most 

of 2009, while at the beginning of this 

year ten pots were added and a gradual 

increase of the production (by approx. 

two pots per month) is planned during 

the course of this year, in accordance 

with improved market conditions. 

Total production of all products was 

88,389 tonnes in 2009, which is 31% 

less than in 2008 when production 

reached 128,838 tonnes. 

At the beginning of this year, 

Talum returned to a 40-hour working 

week after working hours had been 

reduced to 36 hours a week in 2009 

as part of numerous cost reduction 

measures. Moreover, ten electrolysis 

pots were run up, increasing production 

to 48%, in reaction to better market 

conditions and rising aluminium 

prices. 

Talum exports over 80% of its production. 

Its main export markets are: 

Norway (billets), Italy, Austria, Germany 

and France. The main customers 

in Slovenia are the manufacturers 

Impol and Silkem. 

Decreasing: electricity consumption, 

gas emissions, workforce 

Talum has reduced its need for electricity 

to about 600 GWh in 2010, or 

5% of total Slovenian consumption, 

compared to a record of 1,742 GWh 

in 2003, some 14% of the total. In 


2007 Talum paid €90.9 million for consumed 

electricity while consumption for the year totalled 

1.65 billion kWh of electricity; that is, 

Talum paid that year on average about 5.5 euro 

cents per kWh for the entire plant. However, 

according to some CRU reports from that time, 

the power tariff for Talum’ electrolyses was 

around 4.7 US cents per kWh in 2006. 

Talum’s plan is to reduce specific dust 

emissions by 85% and gaseous fluorides 

by 75% during the 2003 to 2010 period. In 

2008 fluoride emissions were significantly 

reduced as a result of the closure of electrolysis 

line B. For the same period, specific 

emissions of greenhouse gases expressed in 

equivalents of CO 2 are to be reduced by 25%. 

Compared to the year 2006 the mass flow of 

total organic compounds (TOC) in the air is 

to be reduced by 45% by the end of 2010. 

There is a workforce reduction programme 

under way, as part of a reorganisation and 

overall cost-cutting measures. At the end of 

last year Talum employed 888 people, compared 

to 980 a year earlier and 1,019 in December 

2007. The average monthly gross wage 

is around €1,650 while the average gross wage 

in Slovenia in February this year was €1,432 

with an average net wage of € 930. 

Alumina 

Talum’s alumina refinery has not been in operation 

since 1991, and all alumina has been 

supplied since then by Hydro Aluminium from 

Sardinia (Italy) via the Slovenian port of Koper. 

This contract was terminated at the end 

of 2009 as the two parties could not agree on 

a price. Consequently, Talum is buying alumina 

from the Bosnian refinery Birac this year. 

The Birac refinery has a capacity to produce 

600.000 tpy and already supplies KAP in Montenegro. 

Though the price was not disclosed, it 

is expected to be around USD400 on Fob basis 

for Talum, similar to the price for KAP. However, 

due to increased demand and this additional 

customer, the Birac refinery has tried 

to increase the price to USD450, according to 

a source with knowledge of the negotiations. 

After Norsk Hydro’s recent purchase of Vale’s 

bauxite and alumina assets, it is not excluded 

that Hydro restores its alumina supply contract 

with Talum in the near future. 

Author 

Goran Djukanovic is an aluminium market 

analyst, located in Podgorica, Montenegro. 

Email: gordju@t-com.me 



�� 

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17

A L U M I N I U M 2 0 1 0 – V o r s c h A U 

Öffnet am 14. September ihre Tore – die 8. Weltmesse mit Kongress: ALUMINIUM 2010 

Opens its gates on 14 September – the 8th World Trade Fair and Conference: ALUMINIUM 2010 

Der countdown läuft – 

ALUMINIUM 2010 wirft ihr Licht voraus 

Wenige Wochen noch, dann wird 

die ALUMINIUM 2010 erneut für 

drei Tage ihre Tore in Essen öffnen 

und die internationale Branchengemeinde 

zu einer beeindruckenden 

Leistungsschau versammeln. Als 

die Messe vor zwei Jahren stattfand, 

schlug die Finanzmarktkrise 

gerade voll auf die Realwirtschaft 

durch. Was wenige Wochen zuvor 

in seiner Tragweite von vielen 

noch nicht wirklich erfasst worden 

war, traf kurz darauf in Form 

von veröffentlichten drastischen 

Auftragseinbrüchen – zunächst in 

der Automobilindustrie und ihren 

Zulieferern, zum Beispiel bei den 

Gießern – mit voller Wucht das 

produzierende Gewerbe und damit 

auch die Aluminiumindustrie. 

Inzwischen haben sich die stürmischen 

Wogen etwas geglättet, die 

Wachstumsprognosen werden sogar 

leicht nach oben korrigiert. Die Produktionszahlen 

der deutschen Halb 

The countdown is running – 

ALUMINIUM 2010 on the horizon 

Only a few more weeks and ALU 

MINIUM 2010 will once more 

be opening its doors in Essen for 

three days to gather the international 

aluminium community for 

an impressive performance display. 

Just when the fair took place 

two years ago, the financial market 

crisis hit out against the real economy. 

What, a few weeks earlier, 

had not yet been grasped to its full 

extent by many, soon became all 

too clear from published reports 

of drastic order collapses – first 

for the automobile industry and its 

suppliers, and then, the full weight 

of the crisis struck other manufacturing 

industries, among them the 

aluminium sector. 

Since then the storm has abated 

somewhat and economic growth fore 

casts have even been adjusted slightly 

upwards. The German semis industry 

production figures are also on a rising 

trend, and this mainly not because of 

stock buildup. 

Against this background ALU 

MINIUM 2010 will now take place in 

a rather more friendly environment. 

The organiser, Reed Exhibitions, is 

breathing more easily in view of the 

expected exhibitor and visitor numbers. 

By now, almost 900 exhibitors 

have booked a stand, whereas a few 

months ago an intermediate figure 

stood at around 650. 

ALUMINIUM 2010, now the 

eighth time is being held, has become 

even more markedly international despite 

the national fairs in China, India 

and Dubai promoted by Reed in recent 

years, which are also showing a 

growth trend. The event in Germany, 


Fotos: Reed Exhibitions Deutschland

A sLP U ME IcN I UA M L2 

0 1 0 – V o r s c h A U A L U M I N I U M 2 0 1 0 – P r E V I E w 

however, is still the leading world 

trade fair for the aluminium industry. 

More than 40 countries will be represented 

at it – some in the national 

pavilions provided for China, India, 

Norway, France, the Netherlands and 

Denmark. Of the more than 20,000 

visitors expected, over half will be 

from abroad. 

In terms of exhibition area too, 

the fair is larger. A ninth hall is available, 

increasing the exhibition area to 

65,000 square metres (2008: 55,000 

m 2 ). The occupation of the halls has 

been reorganised so that sectors as 

primary production, metal processing, 

semis, surface treatment and 

welding and joining will have halls of 

their own. 

New pavilions set the tone 

ALUMINIUM provides a review of 

the entire aluminium industry, its 

equipment suppliers and technology 

partners. At the fair visitors will find 

not only raw material producers, but 

also further processors, refining ➝ 

zeugindustrie verzeichnen ebenfalls 

wieder Zuwächse und dabei dürfte es 

sich nicht vorrangig um die Aufstockung 

von Lagern handeln. 

Vor diesem Hintergrund trifft 

die ALUMINIUM 2010 nun auf ein 

freundlicheres Umfeld. Der Messeveranstalter 

Reed Exhibitions wird 

mit Blick auf die erwarteten Aussteller 

und Besucherzahlen ebenfalls 

aufatmen. Inzwischen haben fast 900 

Aussteller einen Stand gebucht, vor 

einigen Monaten war als Zwischenergebnis 

noch von 650 Ausstellern 

die Rede. 

Die ALUMINIUM 2010, inzwi 

schen zum achten Mal aufgelegt, wird 

noch internationaler – trotz der Ländermessen 

in China, Indien und Dubai, 

die von Reed in den letzten Jahren 

aufgebaut wurden und ebenfalls 

auf Wachstumskurs sind. Die Messe 

in Deutschland bleibt dennoch die 

Weltleitmesse für die Branche. Über 

40 Nationen werden auf ihr vertreten 

sein – zum Teil in Länderpavillons, 

die für China, Indien, Norwegen, 

Frankreich, Niederlande und Däne 

mark vorgesehen sind. Von den über 

20.000 erwarteten Besuchern werden 

mehr als die Hälfte aus dem Ausland 

kommen. 

Auch bei der Ausstellungsfläche 

legt die Messe zu. Eine neunte Halle 

steht zur Verfügung, die Ausstellungsfläche 

wird 65.000 Quadratmeter 

umfassen (2008: 55.000 qm). Die 

Hallenbelegung wird neu ausgerichtet, 

sodass die Branchensegmente Primärproduktion, 

Metallverarbeitung, 

Halbzeuge, Oberflächenbearbeitung 

sowie Schweißen und Fügen eigene 

Hallen bekommen. 

Neue Pavillons setzen Akzente 

Die ALUMINIUM bietet eine Plattform 

für die gesamte Aluminiumindustrie, 

ihre Ausrüster und Technologiepartner. 

Die Besucher finden auf 

der Messe nicht nur Rohstoffhersteller, 

sondern auch Weiterverarbeiter 

und Veredler, Zulieferer für die Automobil 

und Bauindustrie, ebenso 

Anbieter von neuesten Technologien 

in den Bereichen Strangpressen, ➝ 

SETTING THE COURSE IN ROLLING MILL MACHINERY 

TECHNOLOGY FOR FUTURE CONCEPTS 

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

www.achenbach.de 

14.-16.9.2010 

Messe Essen 

Hall 3 K40 

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Walzwerkstechnik, Wärmebehandlung, 

Guss oder Oberflächentechnik. 

Die Messe richtet sich damit an die 

Besucherzielgruppen aus der Aluminium 

herstellenden und verarbeitenden 

Industrie, an die Metallbe und 

verarbeitung inkl. Oberflächenbehandlung, 

darüber hinaus an Fachbesucher 

der Zielmärkte Automotive 

und Transport (Nutz und Schienenfahrzeuge, 

Schiff und Flugzeugbau), 

Maschinenbau, Elektronik und Elektrotechnik, 

Bau und Konstruktionswesen 

sowie Verpackung und Konsumgüter. 

Ausgewählte Themen werden im 

Rahmen eigenständiger Pavillons präsentiert: 

• Gießereipavillon – Produkt 

lösungen aus Aluminiumguss 

• Oberflächenpavillon – Design 

trifft Funktionalität 

• Primärpavillon – Equipment 

und Anlagen zur Aluminium 

gewinnung 

• Schweißen und Fügenpavillon – 

Mit Aluminium verbinden 

• Solarpavillon – Solare Architektur 

mit Aluminium 

• Pavillon für Stückbeschichtung – 

Gesicherte Qualität 

• Magnesium Area – Integrativer 

Bereich zur Förderung und 

Entwicklung des Werkstoffs 

Magnesium. 

Die drei letztgenannten Pavillons 

feiern Premiere in Essen. Dies zeigt, 

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and finishing concerns, suppliers to 

the automobile and building industries 

and providers of the latest technologies 

in the fields of extrusion, rolling 

plant technology, heat treatment, 

casting, and surface treatment. 

Thus, the fair addresses visitor 

groups from the aluminium production 

and processing industries, metal 

treatment and processing including 

surface finishing, and also technical 

specialists from the target markets of 

automotive and transport engineering 

(utility and rail vehicles, marine 

and aircraft engineering), mechanical 

engineering, electronic and electrical 

technology, building and construction, 

as well as packaging and consumer 

goods. 

Selected topics will be presented 

in pavilions of their own, namely: 

• Foundry pavilion – production 

systems and aluminium castings 

• Surface pavilion – design and 

functionality 

• Primary pavilion – equipment and 

plant for aluminium extraction 

• Welding and joining pavilion – 

joining with aluminium 

• Solar pavilion – solar architecture 

with aluminium 

• Pavilion for piecework coating – 

a guarantee of quality 

• Magnesium – an integrative area 

for the promotion and development 

of this special lightweight material. 

The last three of the above men 

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tioned pavilions will celebrate their 

debut in Essen. This shows that Reed 

Exhibitions works continually to extend 

the scope of the fair, establish 

new highlights, capture trends and 

also give a picture of related sectors. 

The new ‘Piecework Coating Pavilion’ 

is being set up with support from 

the GSB International Quality Association 

for the piecework coating of 

components. It will be in hall 4, which 

in the context of the new hall layout is 

devoted to the field of surfaces. In the 

nearby ‘Galeria’ there will again be the 

surface treatment pavilion supported 

by the German association VOA. 

The Solar pavilion specifically addresses 

suppliers of aluminium for 

solar technology. The material has 

meanwhile become established for 

substructure designs, stands, fixing 

systems or frame structures of solar 

modules, and is becoming more and 

more interesting as a sales market for 

the industry. 

With the Magnesium pavilion, for 

the first time ALUMINIUM 2010 is 

devoting a theme pavilion of its own 

to another lightweight material. The 

Magnesium pavilion is supported by 

the European Research Association 

for Magnesium e. V. (EFM). Above all 

for the hardening of aluminium, magnesium 

plays an essential role. Up to 

five percent are added to aluminium 

to improve its strength, machinability 

and weldability of the material. The 

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largest purchasers of AlMg alloys, by 

the way, are the packaging industry 

with 50 percent, followed by the automobile 

industry (35%) and building 

(15%). 


will move to Düsseldorf 

Reed Exhibitions recently announced 

that from 2012 the aluminium fair will 

take place in Düsseldorf. An agreement 

lasting until 2024 has been 

concluded with the Düsseldorf Fair 

administrators. As the reason for this 

change of venue Reed explained that 

there is insufficient capacity for further 

expansion in Essen. “We felt very 

much at home in Essen”, explained 

HansJoachim Erbel, managing director 

of Reed Exhibitions Deutschland, 

“but currently the exhibition space 

capacities of consistently high quality 

that are necessary for the two events 

(ALUMINIUM and Composites Europe) 

are not available in Essen, ➝ 

dass Reed Exhibitions kontinuierlich 

daran arbeitet, die Messeplattform zu 

erweitern, neue Highlights zu setzen, 

Trendthemen aufzugreifen und auch 

angrenzende Branchen mit abzubilden. 

Der neue „Pavillon für Stückbeschichtung“ 

entsteht mit Unterstützung 

der GSB International – Qualitätsgemeinschaft 

für die Stückbeschichtung 

von Bauteilen. Er wird 

sich in Halle 4 befinden, die sich im 

Rahmen der neuen Hallenaufteilung 

dem Thema Oberfläche widmet. In 

der benachbarten „Galeria“ befindet 

sich erneut der Oberflächenpavillon, 

der vom VOA unterstützt wird. 

Der Solarpavillon richtet sich gezielt 

an Anbieter von Aluminium für 

die Solartechnik. Der Werkstoff hat 

sich inzwischen als Basis für Unterbaukonstruktionen, 

Ständer, Befestigungssysteme 

oder Rahmenprofile 

von Solarmodulen durchgesetzt und 

wird für die Industrie als Absatzmarkt 

zunehmend interessanter. Mit 

dem Magnesiumpavillon widmet die 

ALUMINIUM 2010 erstmals einem 

weiteren Leichtbaumaterial einen 

eigenen Themenpavillon. Unterstützt 

wird der Magnesiumpavillon von der 

Europäischen Forschungsgemeinschaft 

Magnesium e. V. (EFM). Magnesium 

spielt vor allem für die Härtung 

von Aluminiumlegierungen eine 

wesentliche Rolle. Bis zu fünf Prozent 

werden dem Aluminium zugesetzt, 

wodurch die Bearbeitung wie auch 

die Schweißbarkeit des Werkstoffs 

verbessert wird. Größter Abnehmer 

der AlMgLegierungen ist übrigens 

die Verpackungsindustrie mit 50 Prozent, 

gefolgt von der Automobilindustrie 

(35%) und dem Bauwesen (15%). 

ALUMINIUM ab 2012 

in Düsseldorf 

Wie der Messeveranstalter Reed Exhibitions 

jüngst mitteilte, wird die 

ALUMINIUM ab 2012 in Düsseldorf 

ausgerichtet. Mit der Messe Düs ➝ 

CUSTOMISED VERSATILITY 

Sustainable solutions for customers worldwide: 

aerospace · automotive · rail · transportation · defence 

ship & yacht building · moulding & tooling 

building & construction · general engineering 

We cordially invite you to visit us at the 

ALUMINIUM 2010 in Essen, Hall 3, B40 

Your Partner for Aluminium 

Rolled Products · Extruded Products · Recycling www.aleris.com


seldorf wurde ein Vertrag mit Laufzeit 

bis 2024 vereinbart. Als Grund 

für den Standortwechsel gab Reed 

die unzureichenden Kapazitäten für 

eine weitere Expansion in Essen an. 

„Wir haben uns in Essen sehr wohl 

gefühlt“, erklärte HansJoachim Erbel, 

Geschäftsführer der Reed Exhibitions 

Deutschland GmbH, „aber 

derzeit stehen in Essen die für diese 

beiden Veranstaltungen (Anm. der 

Red.: ALUMINIUM und Composites 

Europe) notwendigen Kapazitäten an 

durchgängig hochwertigen Ausstel 

lungsflächen leider nicht zur Verfügung, 

sodass ein Umzug an den Rhein 

unumgänglich war.“ 

Das deuten auch die Flächenerweiterungen 

an, die ab 2012 für 

beide Veranstaltungen in Düsseldorf 

geplant sind. Hier werden beide 

Messen vom Start weg über 95.000 

Quadratmeter Hallenfläche belegen: 

80 Prozent dieser Fläche wird durch 

die ALUMINIUM belegt, die in den 

Hallen 9 bis 14 angesiedelt sein wird, 

der Rest ist für die Composites Europe 

vorgesehen, die in den beiden erst 

2007 fertig gestellten Hallen 8a und 

8b stattfinden wird. 

Die Entscheidung ist damit pro 

NordrheinWestfalen gefallen. Dies 

begrüßt auch Christian Wellner, Geschäftsführer 

des Gesamtverbandes 

der Aluminiumindustrie (GDA) – des 

ideellen Trägers und Kongresspartners 

der ALUMINIUM. Wellner verweist 

darauf, dass NRW sowohl bei 

der Produktion von Primäraluminium 

– allein drei von vier deutschen Hütten 

haben hier ihren Standort – als 

auch in der Fertigung von Halbzeugen 

das mit Abstand bedeutsamste Bundesland 

in Deutschland ist. Von den 

74.000 Beschäftigten, die hierzulande 

mit Aluminium ihr Geld verdienen, 

arbeiten 46.000 in NRW, dem größten 

Bundesland der Republik. „Der Um 

Messeveranstalter Reed Exhibitions erwartet über 20.000 Fachbesucher in diesem Jahr 

Organiser Reed Exhibitions expects over 20.000 visitors this year 

satz der Branche liegt hier bei etwa 

acht Milliarden Euro pro Jahr, das 

sind rund 60 Prozent des deutschen 

Branchenumsatzes“, so Wellner. 

Was für die Messe Essen ein 

herber Verlust ist, stellt sich für die 

Messe Düsseldorf als entsprechender 

Gewinn dar. „Mit dem Wechsel beider 

Werkstoffmessen baut der Messestandort 

Düsseldorf seine Rolle als 

international führender Messeplatz 

für die weltweit führenden Metallund 

Kunststoffmessen weiter aus“, 

so der Vorsitzende der Geschäftsführung 

der Messe Düsseldorf, Werner 

M. Dornscheidt. 

Beide Seiten versprechen sich 

von der Einbindung in die Kampagne 

„Bright World of Metals“ zusätzliche 

Synergieeffekte. 

which is why the move to the Rhine 

became inevitable.” 

This is also shown by the area extensions 

planned in Düsseldorf for the 

two events together from 2012. There, 

the two fairs together will occupy well 

over 95,000 square metres of hall surface 

from the beginning: 80 percent 

of that area will be occupied by ALU 

MINIUM, which will be housed in 

halls 9 to 14, and the remainder reserved 

for Composites Europe, which 

will be in halls 8a and 8b, both of them 

first built in 2007. 

That the decision 

went in favour of North 

RhineWestphalia, is 

welcomed by Christian 

Wellner, managing 

director of the German 

Aluminium Association 

GDA, which 

is the ideal backer and 

congress partner for 

ALUMINIUM. North 

RhineWestphalia is by 

far the most important 

federal state in Germany 

– both for the 

production of primary 

aluminium – three out 

of the four smelters in 

Germany are located 

here – and for the production 

of semis too. Of 

the 74,000 employees 

who make their living 

in aluminiumrelated 

industries in Germany, 

46,000 work in this largest state. “Here, 

the turnover of the sector amounts to 

around eight billion euros per year. 

That is roughly 60 percent of the total 

turnover of the aluminium sector in 

Germany”, Mr Wellner says. 

What is a serious loss for the Essen 

fairground, is a correspondingly 

major gain for the Düsseldorf fair. 

“With the move of both material fairs, 

the trade fair location Düsseldorf is 

further strengthening its role as a top 

international leading venue for the 

world’s leading metal and plastics 

fairs“, says Werner M. Dornscheidt, 

chairman of the board of the Düsseldorf 

fair organisation. 

Both sides anticipate synergies 

from their involvement in the ‘Bright 

■ World of Metals’ campaign. ■ 




Führende Aluminiumkonzerne fördern 

den European Aluminium Award 2010 

Leading aluminium players sponsor 

European Aluminium Award 2010 

Once again the European Aluminium 

Award 2010 has got prominent 

support: the global players 

Alcoa, Aleris, Hydro and Rio 

Tinto Alcan will promote the wellknown 

prize as main sponsors. 

The competition is organised by 

the Aluminium Centrum (Houten, 

Netherlands) in cooperation with 

the European and German Aluminium 

Associations EAA and 

GDA and Reed Exhibitions, the organiser 

of ALUMINIUM 2010. 

Every two years, the aluminium industry 

presents the European Aluminium 

Award to honour the best 

new developments in the industry. At 

this year’s aluminium fair, the award 

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Der European Aluminium Award 

hat erneut prominente Unterstützer 

bekommen: Die vier Branchengrößen 

Alcoa, Aleris, Hydro 

und Rio Tinto Alcan fördern als 

Hauptsponsoren den international 

renommierten Preis, der auf Initiative 

des Niederländischen Aluminiumcenters 

in Kooperation mit 

den Aluminiumverbänden EAA 

und GDA sowie dem Messeveranstalter 

Reed Exhibitions Deutschland 

vergeben wird. 

will be presented for the seventh time 

Alle zwei Jahre wird der Preis im 

Rahmen der ALUMINIUM 2010 für 

innovative und kreative Lösungen vergeben. 

In diesem Jahr wird er bereits 

zum siebten Mal verliehen. Insgesamt 

werden sechs Auszeichnungen in den 

zwei Kategorien „Industrieprodukte“ 

und „ConsumerProdukte“ ausgelobt. 

already. All in all, six awards will ➝ Zum ersten Mal werden mit dem ➝ 

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23


Ab 2012 wird die ALUMINIUM-Messe in Düsseldorf ausgerichtet 

From 2012 ALUMINIUM trade show will be taking place in Düsseldorf Photo: Reed Exhibitions 

„Young Designers“Preis Studenten 

und Designer unter 30 Jahren für ihre 

kreativen Ideen ausgezeichnet. Der 

JurySonderpreis wird dieses Jahr an 

die beste Einreichung unter den Aspekten 

„Umwelt, Nachhaltigkeit und 

Energieeffizienz“ vergeben. 

Alle nominierten Produkte und 

Projekte werden auf der ALUMINI 

UM ausgestellt, die Preisübergabe 

findet am 14. September im Rahmen 

der Gala „ALUMINIUM Night“ statt. 

statements der Förderer 

Roland van der Aa, Director Growth 

Practice, Alcoa: „Als einer der führenden 

Innovatoren der Aluminium 

industrie weltweit sind wir stolz, erneut 

einer der Hauptsponsoren des 

European Aluminium Award zu sein 

– einer renommierten Veranstaltung, 

bei der nachhaltige aluminiumintensive 

Lösungen für die Gegenwart und 

Zukunft präsentiert werden. Wir erwarten, 

dass die Jury des Aluminium 

Awards eine wirksame Auswahl trifft, 

um die innovativsten, nachhaltigsten 

und attraktivsten Lösungen zu präsentieren. 

Dies ist zum Nutzen der 

Teilnehmer und dient der Wertschöpfung 

für uns und unsere Branche sowie 

für die Gesellschaft insgesamt.“ 

Roeland Baan, CEO Aleris Europe: 

„Umweltbelange sind nicht mehr 

nur Angelegenheit von Politikern und 

be presented in the 

two categories ‘Industrial 

Products’ and 

‘Consumer Products’. 

For the first time, the 

award for ‘Young Designers’ 

will specifically 

encourage young 

talents. In this category, 

students and designers 

in the under30 age 

group present creative 

ideas and new approaches. 

The ‘Overall 

Jury Award’ focuses on 

the best contribution 

in the area of environmental 

compatibility, 

sustainability and energy 

efficiency. 

All nominated products 

and projects will 

be on display at ALU 

MINIUM 2010, the 

award presentation ceremony will be 

held on 14 September during the gala 

ALUMINIUM night. 

statements of the sponsors 

Roland van der Aa, director Growth 

Practice, Alcoa: “Being one of the 

leading innovators in the global aluminium 

industry, it’s our pleasure and 

honour that we are again one of the 

main sponsors of the European Aluminium 

Award competition – a prestigious 

event that will be showcasing 

sustainable aluminium intensive solutions 

for current and future generations. 

Our expectation is that the jury 

of the 2010 Aluminium Awards will 

uPlanen uModernisieren uoPtiMieren 

Individuelle Anlagen für das Schmelzen und Gießen von 

Nichteisenmetallen – vom grundlegenden Konzept bis 

zum Produktionsbeginn: 

Beratung, Konstruktion, Überwachung von 

Fertigung und Montage, Inbetriebnahme 

Unser Team von erfahrenen Ingenieuren erarbeitet mit 

Ihnen Lösungen, die perfekt an Ihre Produktionsabläufe 

angepasst sind. 

www.ist-engineering.de 

Industrieofen + Stranggieß - Technik GmbH 


s P E c I A L 


undertake an effective selection in 

order to present the most innovative, 

sustainable and attractive solutions. 

This is good for the participants, creates 

value for us and our industry, but 

also for society at large.” 

Roeland Baan, CEO, Aleris Europe: 

“Environmental concerns are not anymore 

the playground for politicians 

and action groups and have, rightly, 

entered the mainstream of our economy. 

The characteristics of aluminium 

make it potentially one of the major 

contributors to a cleaner and more 

energy efficient future for the next 

generations. Aleris, as a global leader 

in aluminium products and applications, 

contributes to this future with 

the development of innovative solutions 

in its extensive R&D facility 

and the various production facilities 

around the world. We strongly believe 

that the European Aluminium Award 

competition is another leading incentive 

to support innovations.” 

Johnny Undeli, executive vice 

president, Hydro: “Aluminium is every 

day finding its way into new applications 

and innovative use. Hydro 

is the leading European aluminium 

company with strong focus on technology 

development and innovation. 

We support the European Aluminium 

Award and hope it will inspire designers, 

manufacturers, architects, builders 

and constructors in their creative 

efforts.” 

Gordon Hamilton, vicepresident, 

Metal Management, Sales & Marketing, 

Rio Tinto Alcan: “Rio Tinto Alcan 

is pleased to sponsor the European 

Aluminium Award 2010 and to salute 

all participants for their creative 

applications of aluminium. Rio Tinto 

Alcan is recognised for its ability to 

continually adapt and enhance its 

competitiveness and this, thanks to 

our firstrate assets and resources, 

our leading smelting technology, our 

capacity for innovation and our commitment 

to sustainable development. 

We constantly strive for the right balance 

between economic, social and 

environmental considerations, which 

drives us to research, innovate and offer 

solutions to our customers ranging 

from thinner foil for packaging to 

lightweighting and energy savings for 

transportation and construction.” 


Bürgerinitiativen, sondern längst im 

Mainstream der Wirtschaft angekommen. 

Mit Aluminium können wir – 

aufgrund seiner Eigenschaften – einen 

der bedeutendsten Beiträge zu einer 

saubereren und energieeffizienteren 

Zukunft für kommende Generationen 

leisten. Aleris, ein weltweit führender 

Anbieter von Aluminiumprodukten 

und anwendungen, trägt durch die 

Entwicklung innovativer Lösungen 

mit seinen umfassenden F&EEinrichtungen 

sowie den verschiedenen 

Produktionsanlagen in aller Welt zu 

dieser Zukunft bei. Wir sind fest davon 

überzeugt, dass die Verleihung 

des European Aluminium Award ein 

weiterer wichtiger Anreiz ist, Innovationen 

zu fördern.“ 

Johnny Undeli, Executive Vice President, 

Hydro: „Täglich findet Aluminium 

den Weg in neue Anwendungen 

und innovative Einsatzbereiche. Hydro 

ist das führende europäische 

Aluminiumunternehmen mit besonderem 

Schwerpunkt auf Technologieentwicklung 

und Innovation. Wir unterstützen 

den European Aluminium 

Award und hoffen, dass er Designer, 

Hersteller, Architekten und das Baugewerbe 

bei ihren kreativen Anstrengungen 

unterstützen wird.“ 

Gordon Hamilton, VicePresident 

Metal Management, Sales & Marketing, 

Rio Tinto Alcan: „Rio Tinto 

freut sich, den European Aluminium 

Award 2010 zu sponsern und alle 

Teilnehmer für ihren kreativen Einsatz 

von Aluminium zu würdigen. 

Rio Tinto Alcan ist für seine Fähigkeit 

bekannt, kontinuierlich seine 

Wettbewerbsfähigkeit anzupassen und 

zu verbessern und das dank unserer 

ausgezeichneten Anlagen und Ressourcen, 

unserer führenden Schmelztechnologie, 

unserer Fülle an Innovationen 

und unserem Engagement für 

nachhaltige Entwicklung. Wir bemühen 

uns fortwährend um die richtige 

Balance zwischen wirtschaftlichen, 

sozialen und ökologischen Überlegungen, 

was uns antreibt zu forschen, 

zu verbessern und unseren Kunden 

passende Angebote zu machen – angefangen 

bei dünner Verpackungsfolie 

bis hin zu leichtgewichtigen und 

energiesparenden Maßnahmen für 

Transport und Konstruktion.“ 

■ ■ 

METALLBAND- 

DICKENMESSUNG 

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� Langzeitstabile Messwerte durch 

schnelle Autokalibrierung 

� Industrie-PC zur Datenerfassung, 

-visualisierung und -archivierung 

� Nachrüstung von Produktionslinien möglich 

ALUMINIUM 2010 / Essen 

14.09. - 16.09.2010 

Halle 2 / Stand 2F04 

www.micro-epsilon.de 

MICRO-EPSILON Messtechnik 

94496 Ortenburg · Tel. 0 85 42/168-0 

info@micro-epsilon.de


ALUMINIUM china 2010 signalisiert 

großes Potenzial im asiatischen Markt 

Nicht nur die Weltausstellung, auch 

die ALUMINIUM China lockte vom 9. 

bis 11. Juni 2010 zahlreiche Besucher 

aus aller Welt nach Shanghai. Für 

die asiatische Aluminiumindustrie ist 

die Messe der wichtigste Treffpunkt 

des Jahres. Die Messe wurde bereits 

zum sechsten Mal durchgeführt. Sie 

zog dieses Jahr mehr als 9.000 Fachbesucher 

aus 80 Ländern an, das ist 

ein leichter Anstieg von drei Prozent 

gegenüber dem vergangenen Jahr. 

Fast die Hälfte der Besucher kam aus 

den Anwenderbranchen wie Bau und 

Konstruktion, Transport, Elektrotechnik 

und Maschinenbau. 

Insgesamt 320 Aussteller aus 30 

Ländern und Regionen präsentierten 

an den drei Messetagen Produkte 

und Lösungen rund um die gesamte 

Wertschöpfungskette der Aluminiumindustrie. 

Dass über 70 Prozent 

der Aussteller aus der internationalen 

Halle bereits vor Messeschluss ihren 

Stand für 2011 erneut gebucht hatten, 

zeigt den hohen Stellenwert der Veranstaltung 

für die Industrie. Mit dabei 

waren führende asiatische Firmen wie 

Chalco, Shandong Nanshan Aluminium, 

Conglin Group, Furukawa Sky 

oder Zhejiang Gko Aluminium sowie 

internationale Key Player der Branche 

wie Wagstaff, Pyrotek, Fata Hunter, 

Dubal oder Aleris, Siemens VAI und 

die SMSGruppe. Gut angenommen 

wurden auch die drei neuen Pavillons 

zu den Themen Primäraluminium, Recycling 

und Auto Parts. 

Ergänzt wurde das Ausstellungsangebot 

durch ein umfassendes dreitägiges 

Kongressprogramm im Rahmen 

der Messe. Branchenexperten 

diskutierten relevante Fragen rund 

um die gesamte Wertschöpfungskette 

der Aluminiumindustrie – von der 

Erzeugung über die Verarbeitung bis 

hin zu Fragen der Anwendung und 

des Recyclings. Ein weiteres Highlight 

war der erste SAE Asia Congress, ein 

Ableger des SAE World Congress, der 

im Rahmen der ALUMINIUM China 

führende Vertreter der Automobilbranche 

zusammenbrachte. Begleitet 

wurde die ALUMINIUM China erneut 

vom China Aluminium Fabrication 

Forum. Initiiert wurde die Konferenz 

von der China Non Ferrous Metal 

Industry Association und dem chinesischen 

BranchenBeratungsunter 

Mehr als 9.000 Fachbesucher aus 80 Ländern besuchten die ALUMINIUM China im Juni 

Over 9.000 visitors from 80 countries came to ALUMINIUM China in June 

ALUMINIUM china 2010 signals 

promising opportunities in Asia 

World Expo 2010 made Shanghai a 

unique city to visit in the year, while 

right alongside this global gathering, 

ALUMINIUM China was brought to 

life at Shanghai New International 

Expo Centre between 9 and 11 June 

2010. Asia’s No. 1 aluminium industry 

gathering for the sixth time opened its 

gates to more than 9,000 trade visitors 

from 80 countries, that is a slight 

increase by three percent compared 

to last year. Nearly 50 percent of total 

visitors were from the applications 

industries, such as building and construction, 

transportation, electronics 

and machinery manufacturing. 

A total of 320 exhibitors from 30 

countries and regions showcased their 

products and solutions along the aluminium 

value chain. The performance 

of the show in Shanghai generated superb 

feedback from participants with 

three fourth of the international hall 

sold for ALUMINIUM China 2011 by 

the end of the trade fair. Leading aluminium 

companies from Asia such as 

Chalco, Shandong Nanshan Aluminium, 

Conglin Group, Furukawa Sky or 

Zhejiang Gko Aluminium were as well 

participating as international key player 

like Wagstaff, Pyrotek, Fata Hunter, 

Dubal or Aleris, Siemens VAI Manu 

nehmen Antaike. 

Die nächste ALUMINIUM China 

wird vom 13. bis 15. Juli 2011 in 

Shanghai stattfinden. 

■ 

facturing and SMS group. The visitors 

also showed great interest at the exhibition 

pavilions primary aluminium, 

recycling and aluminium auto parts. 

The exhibition was accompanied by 

a series of conferences. The threeday 

special forum discussed all relevant 

issues of the whole life cycle, ranging 

from primary aluminium production 

via processing to application and recycling, 

which further enhanced the 

event’s role in providing solutions 

for enterprises. As a major highlight, 

the first SAE Asia Congress, an offshoot 

of SAE World Congress, jointly 

organised by SAE International and 

Reed Exhibitions, brought together 

international car industry experts to 

share their exclusive views on the 

latest sophisticated EV technologies 

with automotive engineers, designers, 

buyers, corporate executives and 

other professionals. The associated 

2010 China Aluminium Fabrication 

Forum was organised by the China 

Non Ferrous Metal Industry Association 

along with China’s information 

and consultancy provider Antaike, as 

well as the ALUMINIUM China. 

Aluminium China 2011 will be held 

from 13 to 15 July at Shanghai New 

International Expo Centre. ■ 


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SMS Siemag 

Überzeugender Mehrwert 

durch integrative Walzwerklösungen 

B. Rieth, Meerbusch 

Das von SMS gelieferte Aluminium-Kaltwalzwerk für Nanshan Light Alloy 

The aluminium cold-rolling plant supplied by SMS for Nanshan Light Alloy 

Wie schafft es ein vom Standort 

Deutschland aus global operierender 

Walzwerkbauer, der als 

Premiumanbieter bekannt ist, ausgerechnet 

in den zurückliegenden 

Krisenzeiten einen überdurchschnittlich 

hohen Auftragseingang 

aus der Aluminiumindustrie zu 

generieren? Allein in den ersten 

Monaten dieses Jahres konnte 

SMS Siemag drei Aufträge mit 

zusammen sechs Gerüsten zum 

Kaltwalzen von Aluminiumbändern 

unterzeichnen und in Kraft 

setzen. Diese Frage stand im 

Zentrum eines Gesprächs mit 

Michael Schäfer, dem Leiter „Produktbereich 

Aluminium“ bei SMS 

Siemag. 

Bis vor nicht allzu langer Zeit wären 

an dieser Stelle Eigenschaften wie die 

besonders robuste und wartungsfreie 

SMS Siemag 

convincing added value from 

integrative rolling plant solutions 

B. Rieth, Meerbusch 

How does a globally active rolling 

plant manufacturer working from 

Germany, recognised as a premium 

supplier, manage even just after 

the recent crisis period to generate 

above-averagely high order intakes 

from the aluminium industry? In 

the first months of this year alone 

SMS Siemag signed three contracts 

with a total of six rolling stands for 

cold rolling aluminium strips and 

has started work on them. This 

question was the focus of a discussion 

with Michael Schäfer, head of 

the Aluminium Product Sector at 

SMS Siemag. 

Until not so long ago, in this connection 

properties such as a particularly 

robust and maintenance-free structure 

of the rolling stand, or the functionality 

and precision of mechanichydraulic 

control elements would 

be mentioned as prerequisites with 

which a supplier made his mark with 

customers. But this is now history, 

since developments have progressed 

so rapidly and so far in recent years 

that no supplier can any longer survive 

in the market without ensuring 

such characteristics that determine 

productivity and product quality. 

Meanwhile, even the complex six- 


Fotos: SMS

high rolling stand, which a few years 

ago was being built by only a few 

plant makers because of its advantages 

for the cold-rolling of the usual 

broad range of strip dimensions, is 

now available much more generally. 

“Even newcomers among Chinese 

aluminium rolling companies now 

ask for the six-high version”, says Mr 

Schäfer, adding that today even Chinese 

rolling plant suppliers are trying 

to break into this technology, albeit 

with slower-running and less wide 

units for the time being. 

A look at SMS Siemag’s reference 

list confirms the preference for sixhigh 

technology convincingly: out of 

15 cold-rolling stands ordered from 

the company in recent years by the 

aluminium industry, 14 were six-high 

stands. The advantages of this design, 

which was originally developed 

in Japan for cold rolling high-grade 

steel strips, emerge above all in the 

cold rolling of aluminium strips with 

more extreme width-to-thickness ratios 

than is usual for steel strips. The 

greater flexibility of a six-high stand 

in relation to varying strip dimensions 

is particularly valuable for aluminium 

strips whose widths range from 

1,000 to over 2,000 mm, all rolled on 

the same unit. Even in terms of strip 

thickness, with hot strip 7 to 8 mm 

thick being rolled – of course, in ➝ 

SMS group in 2009 

Due to the economic crunch in 2009, the 

SMS group faced a collapse in order intake 

to 2.3 billion euros (2008: €5.3bn); 

on the other hand, sales increased to 3.9 

billion euros (+8%) owing to the processing 

of orders still in hand from the previous 

boom years. The pre-tax group result 

rose as well, namely to some 234 million 

euros (+14%). Heinrich Weiss, chairman of 

the SMS group, expects a gradual recovery 

of the company’s relevant markets 

in the second half of 2010. 

“Long-term planning, solid financial 

management, a respect for values and an 

understanding of the cycles of the machine 

and plant construction market have 

formed our group’s business policy for 

decades. That’s why we see the market 


Bauart des Walzgerüstes oder die 

Funktionalität und Präzision von mechanisch-hydraulischen 

Stellgliedern 

als Voraussetzung genannt worden, 

mit denen sich ein Anbieter beim 

Kunden qualifizieren konnte. Doch 

dies ist insofern Geschichte, als die 

Entwicklung der letzten Jahre so 

schnell und so weitreichend voranging, 

dass kein Anbieter mehr ohne 

solche, die Produktivität und Produktqualität 

bestimmende Merkmale 

auf dem Markt überleben kann. 

Inzwischen wird selbst das komplexe 

Sexto-Walzgerüst, das bis vor 

wenigen Jahren nur von wenigen Anlagenbauern 

aufgrund seiner Vorteile 

zum Kaltwalzen der üblichen breiten 

Palette von Bandabmessungen gebaut 

wurde, verbreitet angeboten. „Sogar 

Newcomer unter den chinesischen 

Aluminiumwalzern verlangen heute 

die Sexto-Ausführung“, berichtet 

Schäfer und erwähnt, dass heute 

selbst chinesische Walzwerkanbieter 

sich bereits in dieser Technologie versuchen, 

wenngleich bei langsam laufenden 

und schmaleren Anlagen. 

Ein Blick auf die Referenzliste von 

SMS Siemag betätigt die Bevorzugung 

der Sexto-Technologie überzeugend: 

Von 15 Kaltwalzgerüsten, die das Unternehmen 

in den letzten Jahren von 

der Aluminiumindustrie in Auftrag 

nahm, waren 14 Sexto-Gerüste. Die 

Sales and profit up, order intake down 

downturn continuing since the end of 

2008 as a chance to thoroughly modernise 

our manufacturing capacities”, he says. 

Furthermore, the efforts in technological 

development are being increased and the 

growth fields electrical and automation 

systems, service and environment technology 

expanded. 

India and China will remain the most 

important markets for SMS. India managed 

to continue growing almost unchecked 

through the economic crisis, and 

it will steadily expand its steel industry 

in the coming years. In contrast, demand 

from China is expected to rise only slowly. 

There is new market potential in Central 

and South America and in the Middle 

East, Mr Weiss says. 

t e c h n o l o g y 

Vorteile dieser Konstruktion, die ursprünglich 

in Japan zum Kaltwalzen 

dünner Qualitätsstahlbänder entwickelt 

wurde, zeigen sich vor allem 

beim Kaltwalzen von Aluminiumbändern 

mit extremeren Breiten- zu 

Dickenverhältnissen als bei Stahlbändern 

üblich. Die höhere Flexibilität 

des Sextos in Bezug auf schwankende 

Bandabmessungen kommt bei Aluminiumbändern 

angesichts der von 

1.000 bis über 2.000 mm reichenden 

Bandbreite, die auf einer Anlage gewalzt 

werden, besonders zum Tragen. 

Auch bei den Banddicken, wo Warmband 

mit 7 bis 8 mm – wenngleich 

in mehreren Stichen – auf Dicken bis 

0,1 mm reduziert wird, hat sich das 

Sexto als die vorteilhaftere Lösung 

erwiesen. 

Es darf allerdings nicht übersehen 

werden, dass der Umgang mit 

dieser Gerüstbauart angesichts der 

umfangreicheren Stellmöglichkeiten 

komplexer ist und somit mehr Erfahrung 

verlangt. Dennoch hat sich das 

Sexto bei jenen Betreibern innerhalb 

der chinesischen Aluminiumindustrie, 

die die Erzeugung exportfähiger 

Qualitäten anstreben, als Standard 

durchgesetzt. „Wenn chinesische 

Werke Geldmittel für eine Neuinvestition 

frei bekommen, dann kaufen sie 

gerne das beste, was am Markt verfügbar 

ist“, so Schäfer. 

➝ 

Similar to other plant and machinery 

constructors, for SMS the steel business 

is dominant too. For SMS Siemag the 

aluminium sector accounts for 10 to 20 

percent: at present, owing to the lack 

of spectacular major projects in the 

steel sector, the position occupied by 

aluminium is towards the upper end of 

that range. For SMS Meer the proportion 

of aluminium business is around 20 

percent. 

China remains the driving force of 

the rolling mill business for SMS Siemag. 

In the first half of this year a number of 

orders for new cold-rolling plants were 

received from Chinese companies. In its 

next issue ALUMINIUM will be reporting 

about this. 

29


neue bestimmende 

Faktoren für den Kundennutzen 

Wenn also weder niedrigste Preise 

noch eine Alleinstellung im Anbieten 

der Sexto-Technologie zu den Auftragserfolgen 

führt, welche Faktoren 

sind dann noch für die Erfolge von 

SMS Siemag im Spiel? Schäfer verweist 

hier auf mehrere, sehr unterschiedliche 

Einflüsse: So muss sich 

auch ein Premiumanbieter an Kostenoptimierung 

ausrichten. „Wir bekommen 

zwar manchen Bonus für die 

Vorteile, die wir dem Kunden bieten, 

aber selbstverständlich muss auch 

immer das Preis-Leistungs-Verhältnis 

stimmen“, sagt er. Da der Kostenfaktor 

eine große Rolle bei der Auftragsvergabe 

spielt, setzt SMS Siemag auf eine 

durchgreifende Standardisierung der 

Konstruktionen und Betriebsabläufe. 

Gegenüber dem Zustand von vor 

zehn Jahren spart das Unternehmen 

bei den Mechanikteilen circa 30 Prozent 

der Konstruktionsstunden durch 

eine konsequente Nutzung des vorhandenen 

CAD-Systems, das lückenlos 

bei allen neuen Aufträgen genutzt 

wird. „Damit verfügen wir heute zunehmend 

über komplett gespeicherte 

fertige Module. Änderungen, die bei 

der Anpassung an die Bedingungen 

eines neuen Auftrags entstehen, werden 

ebenfalls elektronisch hinterlegt 

und stehen für künftige Nutzungen 

zur Verfügung“, so Schäfer. Dieses 

Ausmaß der Standardisierung bringt 

auch Einsparungen, zum Beispiel bei 

der Anpassung weiterer Gewerke. 

Fundamentpläne werden nicht mehr 

von Grund auf neu gezeichnet, sondern 

aus der CAD-Datei heraus generiert. 

Ähnliches gilt für weitere Arbeiten 

wie die Erstellung von Dokumentationen 

und Funktionsbeschreibungen. 

Die CAD-Anwendung ist durch ihre 

konsequente Nutzung zur Voraussetzung 

für eine problemlose und kostenoptimierte 

Fertigung geworden. 

Als weiteren Vorteil im Bemühen 

Kosten zu senken sieht Schäfer die eigene 

Fertigung im Werk Hilchenbach. 

Dieses wird gegenwärtig mit einem 

Aufwand von 80 Millionen Euro 

erweitert und auf den modernsten 

Stand gebracht. Da auch hier der Einsatz 

von computerunterstützten Fertigungssystemen 

selbstverständlich ist, 

weist man stolz darauf hin, dass die 

Komponenten eines SMS-Walzwerks 

vom Entwurf bis zur Fertigstellung 

niemals den digitalen Weg verlassen. 

Selbst während der Fertigung bleiben 

die Teile nachverfolgbar und mit den 

zugehörigen Komponenten verknüpft. 

Alles bleibt aufeinander abgestimmt. 

Selbst die Erstellung der Packlisten 

wird vom System übernommen und 

kontrolliert. Damit sind auch Kunden 

in entlegenen Gegenden dagegen geschützt, 

dass sich beim Auspacken der 

Kisten unliebsame Überraschungen 

ergeben, die den Montageplan um 

Wochen verzögern könnten. Auch 

dieser Umstand sowie die mit der 

Fertigung im eigenen Werk verbundenen 

Vormontage und Tests der ➝ 

several passes – to thicknesses down 

to 0.1 mm, the six-high stand has been 

found the best solution. 

It should not be overlooked, however, 

that dealing with stands of this 

design is more complicated because 

of the more extensive adjustment 

options, and so demands greater experience. 

Nevertheless, among those 

operators in China’s aluminium sector 

who aspire to produce exportable 

grades, the six-high mill has become 

standard. “When Chinese plants have 

ready access to finance for new investment, 

they want to buy the best available 

on the market”, says Mr Schäfer. 

new determinants 

for customer benefits 

So if neither the lowest price nor a monopoly 

in offering six-high technology 

lead to success in attracting orders, 

what are the factors that account for 

the success of SMS Siemag? Here, Mr 

Schäfer points to a number of very different 

influences. A premium supplier 

must pay attention to cost optimisation. 

“Certainly, we benefit from the 

advantages that we offer our customers, 

but of course the price-performance 

ratio always has to be right”, he 

explains. Since the cost factor plays a 

major part in determining the award 

of contracts, SMS Siemag is committed 

to thorough standardisation of its 

designs and operating sequences. 

Compared with the situation ten 

years ago, for mechanical equipment 

the company saves around 30 percent 

of design and construction time 

thanks to consistent use of the existing 

CAD system, which is used without 

fail for every new order. “Increasingly 

therefore, we have complete, finished 

modules already saved. Changes that 

have to be made for adaptation to 

the conditions of a new contract are 

also stored electronically and remain 

available for future use”, he points 

out. This level of standardisation also 

results in savings, for example in the 

adaptation of further plants. Foundation 

plans are no longer drawn 

up from scratch, but generated from 

the CAD files. The same applies to 

other work such as the preparation of 

documentation and function descriptions. 

Thanks to its consistent use, 

Hightech und Visualisierung der Prozessparameter kennzeichnen den Steuerstand 

Advanced technology and visualisation of the process parameters characterise the 

control console ➝ 


Dateiname: AP_06_2010_LNS.pdf; Nettoformat:(297.00 x 420.00 mm); Datum: 27. May 2010 09:28:25; PDF-CMYK; L. N. Schaffrath DruckMedien 

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Trimet hat 130 Millionen Euro in die Standorte Harzgerode und Sömmerda investiert 

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Trimet Aluminium baut ihr 

Druckgussgeschäft weiter aus 

Deutschlands größter Aluminiumproduzent, 

die Trimet 

Aluminium AG, Essen, 

feierte am 7. Mai 2010 ihr 

25jähriges Bestehen. In seiner 

relativ kurzen Historie 

hat sich das Unternehmen 

vom Metallhändler und Hüttenproduzenten 

zu einem 

Technologiekonzern rund 

um den Werkstoff Aluminium 

entwickelt. Mit seiner 

Automotive-Sparte und dem 

Ausbau des Druckgussgeschäfts 

an den Standorten 

Harzgerode und Sömmerda 

hat sich Trimet ein weiteres 

attraktives Geschäftsfeld aufgebaut, 

das gute Zukunftschancen 

hat. Seit der Übernahme 

der beiden Produktionsbetriebe 

in Harzgerode 

und Sömmerda im Jahr 

2001 wird Trimet an beiden 

ostdeutschen Standorten am 

Jahresende 2010 insgesamt 

130 Millionen Euro in neue 

Anlagen A investiert haben, für 

2011 2011 sind sind weitere Investitionen 

onen in Höhe Höhe von vo 25 Millionen 

nen Euro Euro geplant. geplant. 

DD 

APT ALUMINIUM NEWS 2 | 06-2008 

NEWS 

ABB wins aluminium 

project in Canada 4 

Scottish trains utilising 

lightweight aluminium 

ceiling units 5 

RECYCLING 

Am Trimet Standort Harzgerode sind zurzeit 511 Mitarbeiter und 41 Auszubildende beschäftigt. 

Anhalt und der MWS Metall- der Forderungen hätte verzichwerk 

Sömmerda GmbH Thüten müssen, übernahm Trimet 

rigen. Die Übernahme geschah kurzerhandbeideStandorte.Bei 

er er Trimet Trimet Geschäftsfeld 

Geschäftsfeld ff eher eher ungewollt, denn Trimet der Übernahme durch Trimet 

Automotive Automotive entstand entstand hattehoheF 

hatte hohe Forderungen inzwei- umfasste die Produktpalette an 

im Jahr Jahr 2001 2001 durch durch die 

stelliger stelliger Millionenh Millionenhöhe an den beiden Standorten viele Low- 

Übernahme Übernahme der der Metallwerke 

Metallwerke Vorbesitzer. Vorbesitzer. rr DDa 

a man man bei eeiner 

Cost Produkte wie Motorträger, 

Harzgerode Harzgerode GmbH GmbH in Sachsen- Sachsen- Insolve Insolvenz l nz auf einem einem Großteil Großteil Kupplungspedale, Ölwannen, 

FAIRS 

Ihr Ihr Partner Partner für Alum�n�umoberflächen 

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Federal-Mogul 

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Fe 

OFFICIAL INTERNATIONAL 

MEDIA PARTNER 

Volume ume me e 86 886 

86 · June June Ju 2010 201 010 

International Journal for Industry, Research arch arch h and an and App Ap Application lication 

Internationale Internationale Fachzeitschrift 

Fachzeitschrift 

WW ii rr tt s c h a ff t t · · T e c h n ii k · · W ii s s e n s c h a ff tt 

4. Juni 2010 

15. Jahrgang 

www.alu-web.de 

➔ 

Fortsetzung Seite 2 

BDW BDW technologies technologies übernimmt übernimmt Alcoa-Werk Alcoa-Werk in Soest 

Tel. Tel. 02 02 11/641 11/641 27 27 90 90 

Die Die BDW BDW DD technologies technologies 

aus aus 

dem dem bayerischen baye aa rischen Markt Markt 

Schwaben Schwaben hat aa mit mit 

Wirkung Wirkung 

zum zum 1. 1. Mai Mai das das Soester Soester 

Alcoa-Werk Alcoa-We - rk übernommen. 

übernommen. 

Das Das neue neue Unternehmen 

Unternehmen 

formiert formiert unter unter dem dem Namen Namen 

BDW BDW DD technologies technologies 

Soest Soest 

GmbH. GmbH. Alle Alle 250 250 Arbeiter Arbeiter 

behalten behalten ihren ihren Arbeitsplatz. 

Arbeitsplatz. aa 

Das Das Werk Werk soll, soll, so die PlaPlanungen,nungen, weiter weiter ausgebaut ausgebaut 

werden. werden. 

Volume VI / Issue 2/3 . June 2010 

AUTOMOTIVE 

Novelis Fusion: 

new technologies 

for more lightweight 

construction 12 

Winners of die-casting 

competition named 13 

Two-level store for 

extruded profiles 14 

EXTRUSION 

Energy-efficient billet 

heating in a gas-fired 

furnace 15 

Bactericide-free 

cutting fluids without 

bacterial growth 16 

MACHINING 

HI-LIGHTS 

100 years of alufoil 

and still moving 

forward 7 

Blitzschnelle Blitzschnelle Befestigungstechnik 

Befestigungstechnik 

The London view 20 

Bolzenschweißen 

in Millisekunden 

Foto: TRIMET ALUMINIUM AG 

beste 

www.hbs-info.de 

Getriebestützen, Leiterrahmen 

oder Zylinderkopfhauben 

und war auf wenige Kunden 

beschränkt. „In den ersten zwei, 

drei Jahren nach der Übernahme 

hatten wir noch keine ein- 

Ausgabe 6 |10 

Verbindungstechnik 

Special: Special: Titan Tita 

www.metall-web.de 

met me eta tallll-w -we web.d 

b.de 

Vorstellung einer neuen Fügetechnik für 

Solarkollektorrahmen aus Aluminium 

und eines neu entwickelten SZB-Grobgewindebolzens 

Innovation 

4 - 5 

Fachbeitrag von Horst Gers, Honsel: 

Prozessoptimierung und neue Werkstoffe: 

Innovationen bei Strangpressprofilen 

für Fahrzeug-Spaceframes 

Report Schweiz 

Themenschwerpunkt zur Schweizer 

Aluminiumindustrie: Märkte, 

Unternehmen, Innovationen 


as as Alcoa-Werk Alcoa-We - rk in Soest Soest Rahmenstruktur Rahmenstruktur einzubinden 

einzubinden. 

ist die Wiege Wiege des des heuheu- BDW BDW DD ttechnologies 

echnologies hat als erserstigentigen Audi-Space-Fra 

Audi-Space-Fra- FF - ter Druckgießer Druckgießer großflächige 

großflächige 

me. me. In dem dem Werk Werk wurden wurden die 

Strukturbauteile Strukturbauteile erfolgreich erfolgr ff eich in 

erfor erforderlichen ff derlichen Komponenten 

Komponenten einer einer Großserie Großserie hergestellt hergestellt und und 

-- von von Honsel Honsel zugelieferte zugelieferte ProPro- ist seitdem seitdem unangefochtener 

unangefochtener 

file und und Gussknoten Gussknoten produziert produziert Marktführer Marktführer in diesem diesem Bereich. Bereich. 

und und bearbeitet. bearbeitet. 

Aus Aus dieser dieser Sicht Sicht macht macht die 

In der der Folgezeit Folgezeit ging ging die 

Zusammenführung Zusammenführung der Space- Space- 

Entwicklung Entwicklung dahin, dahin, in zunehzuneh- Frame-Komponenten Frame-Komponenten Sinn. Sinn. 

mendemmendem Maße Maße dünnwa dünnwandige nn ndige Die Die Alcoa-Druckgießerei 

Alcoa-Druckgießerei 

Gusskomponenten Gusskomponenten aus aus AlumiAlumi- erzielte erzielte nach nach eigenen eigenen Angaben Angaben 

nium-Knetwerkstoffennium-Knetwerkstoffen 

ff in die 

bisher bisher einen einen jährlichen jährlichen Umsatz Umsatz 

von von 25 Mio. Mio. Euro. Euro. 

Aus Aus Sicht Sicht von von BDW BDW 

erscheint erscheint die Übernahme Übernahme auch auch 

deshalb deshalb attraktiv, attr tt aktiv, vv weil weil 

man man in 

den den nächsten nächsten Jahren Jahren einen einen starstarkenken Anstieg Anstieg der der Nachfrage Nachfrage nach nach 

diesen diesen Komponenten Komponenten erwartet. erwartet. 

Als Umsatzziel Umsatzziel werden werden 50 bis 

60 Millionen Millionen Euro Euro genannt. genannt. Um Um 

dieses dieses Ziel Ziel zu erreichen, erreichen, soll soll die 

Anzahl Anzahl der Mitarbeiter Mitarbeiter in Soest Soest 

auf 400 400 wachsen. wachsen. 

Da die Stadt Stadt bereits bereits vor JahJahren ein 20.000 20.000 Quadratmeter 

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großes großes Grundstücke Grundstücke für etwaietwaige Expansionen Expansionen von von Alcoa Alcoa 

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Wir Wir stehen stehen für 40-jährige 40-jährige Fachkompetenz Fachkompetenz in der der Entwicklung 

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Wir Wir sind sind zertifiziert zertifiziert nach nach 

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Alles Alles aus aus einer einer Hand Hand – – direkt direkt vom vom Hersteller Hersteller 

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Telefon: Telefon: 08153 08153 885-0 885-0 

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Automatica Automatica 2010 2010 in München München vom vom 8.–11.6.2010, 

8.–11.6.2010, 

Halle Halle B 1, Stand Stand D 110 110 

Special 2010: 

Aluminium casting 

BDW – Technological 

expertise in aluminium 

diecasting 

Aluminium recycling 

at Aluminium Norf 

60 years of 

Chinese alu minium 

industry in retrospect 

66 

Pressen Pressen von von Titanpulver Titanpulver 

Titanhalbzeugherstellung 

Titanhalbzeugherstellung 

Titan Titan im Automobilbau 

Automobilbau 

Kippbarer Kippbarer Schmelz-/Gießofen 

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NE-Metalle NE-Metalle sind sind modernes modernes Leben Leben 

Einzel-Verkaufpreis: Einzel-Verkaufpreis: 21,00 21,00 € € 

64. 64. Jahrgang Jahrgang · · Juni Juni 2010 2010 

Internationale Internationale Fachzeitschrift 

Fachzeitschrift 

für Wirtschaft, Wirtschaft, Technik, Technik, Wissenschaft 

Wissenschaft 

9 - 16 

Aluminium Praxis ist wie in den Vorjahren 

exklusiv „offizielle Messezeitung“ der 

„ALUMINIUM 2010“. 

www.bdw-technologies.com 

www.bdw ww ww -techno nologie gies.cc cccc om o 

World Expo makes ALUMINIUM China 

an experience not to be missed 

Kobe Steel to set up 

aluminium forged Back in 2009, ALUMINparts 

company in IUM China managed to 

China 2 be a record-breaking 

Gautschi Engineer- 

event even in the miding 

new member of 

dle of the industry-wide 

Ebner group 2 

crisis. This year, with 

World Expo 2010 held 

Hydro’s first 

alongside, the event is 

quarter 2010 3 

expecting over 10,000 

visiting professionals 

from countries all 

Trimet to purchase over the world, many 

metal for Honsel 4 of which are just overcoming 

the recession 

and are now hoping to 

celebrate and catch up 

with the recovery led 

by Asia and especially 

Scrap exports to 

China. 

China threaten supplies 

in Europe in the 

long term 6 

Alcoa dedicates 

expanded recycling 

operations 6 

Expectations for 

METEF-FOUNDEQ 

2010 met 8 

ALUMINIUM 2010: 

Trade fair growing 

with new hall 

structure 9 

Furnace charging 

with automatic 

systems 10 

International study 

confirms aluminium 

advantage 11 

8 

HILLER HI HI HH LL LL ER E GR GR GROUP RR OU OUUPPPP UU 

ALU-PROFIL-TECH�IK 

ALU-PROFIL-TECH�IK 

Die Die Die DD edle dd 

Oberfläc�e Oberf Obe O fläc�e 

äc 

...gibt‘s ...gibt‘s in in allen allen 

Farben Farben und und Systemen! Systemen! 

Pulverbeschichtung 

Pulverbeschichtung 

und und Anodisation: 

Anodisation: 

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KÖNIG KÖNIG Metallveredelung Metallveredelung GmbH GmbH • D-79787 D-79787 Lauchr�ngen 

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Telefon Telefon 0049 0049 (0) 7741 7741 6097-0 6097-0 • www.koen�gmetall.de 

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– and his ALUMINIUM 

China event team, said: “The 

success of this event rides on 

China’s explosive economic 

growth in the past; even 2009 

was no exception. Many of 

our exhibitors were affected 

by the recession and are faced 

with real issues of fiercer competition 

and drop in demand. 

But the return they received 

through participation at 

ALUMINIUM China proved 

that the event is a most costeffective 

way to create direct 

contacts which generate new 

business opportunities and 

sales leads, while in a macro 

way, China remains as the 

most dynamic market even in 

2009 made a remarkable 

the face of worldwide difficul- 

impact on China and the 

ties. Seeing clear signs that the 

world’s aluminium calendar. 

recovery is around the corner, 

Despite the harsh economic 

and with China still leading 

climate in most countries the 

the trend, we firmly believe 

whole year round, alumin- 

that ALUMINIUM China 

ium consumption in China 

2010 will become the biggest 

reached 14.2 million tonnes, automotive and real estate, Centre, with its excellent ing worldwide – managed to and most powerful such event 

an 11% increase above that China’s aluminium industry facilities, a perfect location achieve impressive positive ever.” 

of the year 2008, which pro- has turned around and is now with ideal timing for another results even in the middle Granted that over 80% of 

vided strong support to the continuing its upward trend outstanding ALUMINIUM of the period of crisis. The the reserved space has been 

global aluminium market. A thanks to favourable policies China between 9 to 11 June. event achieved 30% growth sold five months before the 

year-on-year 41.5% rise in the and measures adopted by the ALUMINIUM China is in terms of visitor numbers start of the show, especially 

primary aluminium price was Chinese government to boost an annual aluminium-indus- (8,786 visitors and buyers in in hall W5 where most inter- 

recorded as of December 2009 the economy. As widely estitry event which has become 2009, compared with 6,744 national exhibitors locate, in 

(stock price on 25 December mated, global aluminium the leading such event in in 2008), making this a peak which 95% of the exhibiting 

2009 was 16,145 RMB/t, com- demand will remain led by Asia and attracts hundreds event among the past five. area is booked up and there 

pared to the price a year earlier, the growing Chinese market of top industrial companies The on-site rebooking rate are still many more compa- 

which stood at 11,410 RMB/ and will stay stable or even and thousands of profession- of nearly 51% was another nies on the waiting list, Reed 

t). With clear signs showing increase in 2010. 

als from over 90 countries to record high. 

Exhibitions is anticipating 

that the country has made its Precisely at this point of Shanghai, with the spin-off of Dealing with questions yet another record-breaking 

way out of the crisis, China is time, Shanghai, as the host of facilitating new partnerships about market sentiment and event that will be attended by 

now becoming the wellspring World Expo 2010 – the global and business deals. In 2009, what new highlights the 2010 over 10,000 visiting profes- 

of the momentum for recov- celebration with an expected in opposition to the down- event will come up with, sionals seeking to network 

ery. With a strong perform- 70 million visitors arriving ward trend experienced by Edwin Tan, Vice-President for with providers and to view 

ance by several aluminium in the city between May and many industry players, this Projects & Business Develop- a better selection of quality 

consuming industries such October – makes the Shang- trade fair – the year’s largest ment of the organiser – Reed 

as infrastructure projects, hai New International Expo aluminium industry gather- Exhibitions Greater China 

It came as a surprise, even xite, alumina and aluminium 

high quality and efficient cost wegian state’s ownership in 

for experts close to the alu- assets with its own business. 

base of the contributed assets the company being reduced 

minium industry. Norsk The Brazilian mining com- 

will also significantly improve from 43.8% to 34.5%. 

Hydro has signed an agreepany Vale will receive a total 

its financial position. 

Vale will at closing of the 

ment to take over Vale’s consideration comprising 

To partly finance the trans- transaction contribute 60% 

aluminium business to USD1.1 billion in cash and 

action, support the company’s in Paragominas, 57% in Alu- 

form a resource-rich and new Hydro shares equiva- 

investment grade rating and norte, 51% in Albras and 61% 

fully integrated aluminium lent to 22 percent ownership 

capacity to implement future in the CAP alumina refinery 

company, securing Hydro's of its outstanding shares. As 

projects, Hydro intends to project. Prior to the combina- 

bauxite supplies in a 100- of 30 April and consider- The deal will consider- launch a fully underwritten tion, Hydro already has 34% 

year perspective. The deal ing assumed net debt, this ably strengthen Hydro’s rights issue of NOK10 bil- ownership in Alunorte and 

equates a total considera- equates to a total considera- position in bauxite mining lion (approx. USD1.75bn). 20% ownership in CAP. 

tion of USD4.9 billion. tion of USD4.9 billion. and alumina refining which, At closing of the combination The closing of the transac- 

along with energy, are the and following the rights issue, tion with Vale is expected in 

Hydro has entered into 

most important input factors a private placement to Vale of fourth quarter 2010. 

an agreement to combine 

in aluminium production. 22% of Hydro’s outstanding 

the majority of Vale’s bau- 

Hydro emphasizes that the shares will result in the Nor- 

ALUMINIUM China is expecting over 10,000 visitors from countries all over the world 

Hydro takes over Vale's aluminium business 

The transaction will provide 

Hydro with high-quality 

assets in Brazil, comprising 

full control and ownership of 

Photo: Reed China 

Paragominas, one of the largest 

bauxite mines in the world. 

Moreover, Hydro will receive a 

91% ownership in the world’s 

largest alumina refinery Alunorte, 

51% ownership in the 

Albras aluminium plant and 

81% ownership in the CAP 

alumina refinery project. 

� Continued on page 2 

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Erzeugnisse werden vom Kunden im 

Hinblick auf geforderte immer kürzer 

werdende Lieferzeiten gerne als 

Mehrwert angenommen. 

Vernetzung durch Plug and Work 

Im Bereich der Elektrik und Automation 

verfolgt SMS Siemag konsequent 

den Weg der Systemintegration und 

Vorabinbetriebnahme seiner technologischen 

Lösungen. Damit verbunden 

ist die Entwicklung des „Plug 

& Work“-Konzeptes, das in Art und 

Umfang heute noch einzigartig ist. 

Die schnelle Akzeptanz am Markt 

ist ein deutliches Zeichen dafür, dass 

die Walzwerksbetreiber die daraus 

ableitbaren Vorteile schnell erkannt 

haben. Diese liegen in erster Linie 

darin, dass sämtliche Steuerpulte, 

Schaltschränke und Rechensysteme 

vor der Lieferung an den Kunden bei 

SMS Siemag aufgebaut und miteinander 

vernetzt werden. Die künftigen 

Betreiber der Walzwerke schätzen 

besonders die Möglichkeit, ihre zukünftige 

Anlage bereits vor Auslieferung 

und auch während der Montage 

im simulierten Echtzeitbetrieb kennen 

zu lernen und sich mit der Bedienung 

vertraut zu machen. So können 

beispielsweise alle Vorgänge bis hin 

zum kompletten Produktionsprozess 

in Verbindung mit dem künftigen 

Betrieb des Walzwerkes bereits vor 

dessen Auslieferung, Montage und 

Inbetriebnahme als realer Prozess simuliert 

werden. 

Nebenbei bietet der Plug & Work- 

Test durch die aktive Teilnahme 

des Kunden die Möglichkeit, Dokumentationsunterlagen 

und Bedienhandbücher 

auf Vollständigkeit und 

Sinnhaftigkeit zu prüfen sowie auf individuelle 

Fahr- und Ablaufgewohnheiten 

abzustimmen. Der Bediener 

sitzt dabei an dem Steuerpult, das er 

später an der Anlage wieder vorfindet 

und spielt die verschiedenen Prozessschritte 

durch, für die er ein sofortiges 

Feedback erhält. Damit ermöglicht 

Plug and Work neben dem Training 

der künftigen Bedienmannschaft eine 

Optimierung der Abläufe unter Einbeziehung 

von bereits vorliegenden 

Kundenerfahrungen. Plug and Work 

hat sich auch als vorteilhaft bei der 

Durchführung größerer Modernisie- 

rungsmaßnahmen erwiesen. Hier 

können die mit der alten Anlage vertrauten 

Mitarbeiter bereits während 

der Durchführung der Modernisierungsarbeiten 

auf der neuen Anlage 

geschult werden. 

Plug & Work sichert SMS Siemag 

zurzeit eine Alleinstellung am Markt. 

Möglich wurde dies durch den in 

den letzten sieben bis acht Jahren 

deutlich ausgebauten Bereich „Elektrik 

und Automation“. Waren hier 

anfangs weniger als 300 Mitarbeiter 

tätig, beschäftigt dieser Bereich heute 

weltweit über 1.000 Mitarbeiter. Neben 

den SMS-Betrieben in Hilchenbach 

und Düsseldorf verfügen auch 

die Niederlassungen in China, Indien 

und den USA über eigene Testfelder 

und sichern so die Qualität der eigenen 

Elektrik und Automation. 

Airwash-Abluftreinigungsanlage 

Airwash exhaust air cleaning system 

Nach Einschätzung von Michael Schäfer 

setzt sich der Trend zur Nutzung 

von Plug and Work auch im Aluminiumbereich 

fort. 

Virtual Reality und „Mock-up“ – 

eine weitere Stufe zur 

integrierten Walzwerkslösung 

Standardisierung zu nutzen heißt, 

sie zu leben. Mit anderen Worten: 

Es ist nicht damit getan, vereinheitlichte 

Bauteile in einer Datenbank 

zu hinterlegen, sondern sie im Rahmen 

einer Erfahrungsdokumentation 

aus der gesamten Abwicklungskette 

eines Auftrages zu speichern und an- 

the application of CAD has become 

a prerequisite for problem-free and 

cost-optimised production. 

As a further advantage in the effort 

to reduce costs, Schäfer points 

to the in-house manufacturing at the 

plant in Hilchenbach. At present the 

company’s production facilities are 

being extended and brought up to the 

most modern standards, at a cost of 80 

million euros. Since here too the use 

of computer-supported production 

systems is obviously involved, great 

pride is expressed in the fact that 

from the design stage up to the finished 

product the components of an 

SMS rolling plant never depart from 

the digital route. Even during production 

the parts can be traced and linked 

with their associated components. 

Everything is matched to everything 

else. Even the preparation of packing 

lists is performed and checked by the 

system. In this way, even customers 

in remote locations can be sure that 

when they unpack the crates, there 

will be no unpleasant surprises that 

could hold up the assembly process 

for weeks. This fact too, along with 

the pre-assembly and product testing 

made possible by the production facilities 

available in-house, are gladly 

accepted as added value in light of the 

ever-shorted delivery times called for. 

Simulation of the real production 

process by Plug & Work 

In the area of electric equipment and 

automation SMS Siemag consistently 

follows the route of system integration 

and advance commissioning for 

its technological solutions. Connected 

with this is the development of the 

‘Plug & Work’ concept, which is today 

unique in type and scope. 

Prompt acceptance by the market 

is a clear sign that rolling plant operators 

quickly recognised the advantages 

stemming from this. These consist 

mainly in the fact that all the control 

consoles, switch cabinets and computer 

systems are built at SMS and 

interconnected before delivery to the 

customer. The future operators of rolling 

plants particularly appreciate the 

possibility of familiarising themselves 

with their future plant already before 

delivery, even during its assembly, 


in simulated real-time operation and 

gaining confidence about its workings. 

For example, all processes up to 

and including complete production 

processes in combination with the future 

operation of the rolling mill can 

be simulated as real processes already 

before the equipment is delivered, assembled 

on-site and commissioned. 

Besides, owing to the active participation 

of the customer the Plug 

& Work test provides him with the 

possibility of checking documentation 

and operating handbook texts 

for completeness and rationality, and 

adapting them to individual operating 

and sequence habits. For this, 

the operator sits at the same control 

console that he will later be using at 

his own works and goes through the 

various process steps, obtaining immediate 

feedback as he does so. Thus 

Plug & Work, besides training the 

future operating workforce, enables 

the sequences to be optimised while 

taking into account already available 

customer experience. Plug & Work 

has also proved advantageous when 

implementing major modernisation 

measures. In such cases the personnel 

who are confident with the old plant 

can already be trained to use the new 

equipment while the modernisation 

work is in progress. 

For the time being Plug & Work has 

secured for SMS a monopoly in the 

market. This was made possible by the 

substantial extension of the ‘Electrical 

and Automation’ (E & A) sector over 

the past seven or eight years. Whereas 

initially fewer than 300 people were 

active in the sector, today more than 

1,000 employees worldwide are active 

in it. Besides the SMS operations 

in Hilchenbach and Düsseldorf, the 

establishments in China, India and the 

USA all have their own test facilities 

and can so ensure the quality of their 

E & A systems. In Mr Schäfer’s estimation 

the trend toward using Plug & 

Work in the aluminium sector as well 

is continuing. 

Virtual Reality and ‘Mock-up’ – 

a further step towards the 

integrated rolling plant solution 

Using standardisation means living it. 

In other words: the procedure is not 


just to store standard components in 

a database, but rather, to save them 

as part of the experience documented 

from the entire implementation chain 

of an order and thus make them available 

to everyone involved in a new 

project. With this objective SMS Siemag 

has now made a successful start 

in developing a new model, known 

within the company as ‘Mock-up’. 

Within the framework of the model 

all sections of the company involved 

in a project, namely sales, design, automation 

and electrical equipment, 

development, production, assembly 

and commissioning staff, working together, 

create an image in a ‘Virtual 

Reality’ network and go over it on the 

basis of that platform. The aim is to 

find an overall solution that is optimised 

for the tasks in hand and for the 

customer, taking into account all the 

experience gathered in the various divisions 

of the company. All those involved 

can make simultaneous inputs 

to the project and, together, define the 

optimum standard in each case. 

As the latest extension of the integrative 

rolling plant concept, SMS 

Siemag supplies coolant-lubricants 

developed in-house (on this, see ALU- 

MINIUM 7/8-2009, pp. 40-42). These 

products are optimised for every application 

and ensure that the operator 

will be able to maintain the guaranteed 

performance levels. This too is an important 

cornerstone for the building 

of trust between the partners and is a 

manifest sign of SMS’s determination 

to extend its service sector further. 

With its forward-looking developments 

such as Plug & Work and Virtual 

Reality, SMS Siemag has issued a 

clear message that the classical division 

of rolling plant construction into 

its mechanical and electrical aspects 

has almost disappeared. This represents 

added value for the customer, 

the benefit of which clearly outweighs 

the costs involved. 

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. 


schließend allen Beteiligten an einem 

neuen Projekt verfügbar zu machen. 

Mit dieser Zielsetzung hat SMS Siemag 

erfolgreich damit begonnen, ein 

neues, intern als „Mock-up“ bezeichnetes 

Modell zu entwickeln. 

Im Rahmen des Modells können 

alle an einem Projekt beteiligten Stellen 

des Hauses, also Vertrieb, Konstruktion, 

Automation und Elektrik, 

Entwicklung, Fertigung sowie Monteure 

und Inbetriebnehmer in einem 

Netzwerk vereint das neue Projekt 

als „Virtual Reality“ abbilden und auf 

dieser Plattform durchsprechen. Ziel 

ist die Findung einer aufgaben- und 

kundenoptimierten Gesamtlösung 

unter Einbeziehung aller an den unterschiedlichen 

Stellen des Hauses 

gesammelten Erfahrungen. Alle Beteiligten 

bringen sich gleichzeitig in das 

Projekt ein und definieren gemeinsam 

den jeweils optimalen Standard. 

Als neueste Erweiterung des 

integrativen Walzwerkkonzeptes 

liefert SMS Siemag Lubrication 

Kühlschmierstoffe aus eigener Entwicklung 

(siehe dazu ALUMINIUM 

7/8-2009, S. 40-42). Diese werden für 

jeden Anwendungsfall optimiert und 

sichern dem Betreiber die Einhaltung 

der zugesagten Garantien. Dieser 

wichtige Baustein der Vertrauensbildung 

zwischen den Partnern ist ein 

sichtbares Zeichen, dass SMS Siemag 

weiterhin bestrebt ist, den Servicebereich 

auszubauen. 

Mit ihren wegweisenden Entwicklungen 

wie Plug and Work und Virtual 

Reality hat SMS Siemag ein deutliches 

Zeichen dafür gesetzt, dass die klassische 

Aufteilung des Walzwerkbaus 

in Mechanik und Elektrik praktisch 

aufgehoben ist. Hieraus entsteht für 

den Kunden ein Mehrwert, bei dem 

der Nutzen die verbundenen Kosten 

deutlich überwiegt. 

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. 

SMS group is an exhibitor at ALU- 

MINIUM 2010. Hall 3, Stand A40. 

33

Aberle 


Erdbebensicheres Hochregallager 

Aberle Automation realisiert innovatives 

Steuerungskonzept für chinesisches Folienwalzwerk 

800 Erdbeben im Jahr weltweit 

erreichen auf der Richterskala die 

Stärke 5 bis 6. Einige davon ereilen 

die Region rund um die südchinesische 

Zwei-Millionen-Stadt 

Xiamen. Für die hier ansässige 

Industrie heißt es, Prozesse zu installieren, 

die trotz der immer wiederkehrenden 

Erdstöße reibungslos 

funktionieren. Der chinesische 

Aluminiumfolienhersteller Xiamen 

Xiashun Aluminium Foil Ltd. hat 

für den Materialfluss ein Intralo- 

gistiksystem mit Materialfluss- 

und Warehouse-Management von 

Aberle Automation errichtet. 

Xiamen Xiashun Aluminium Foil 

stand vor der Aufgabe, in der Sonderwirtschaftszone 

neue Produktionsanlagen 

mit zum Teil hochsensiblen 

Steuerungseinheiten zu installieren. 

Das Unternehmen, das auch weltweit 

zu den führenden seiner Sparte 

gehört, errichtete 2008 eines der 

modernsten Aluminiumwalzwerke 

Asiens, unter anderem zur Fertigung 

Komfortable Lagerverwaltung mit Aberle 

PMS-W in der Praxis 

von Hightechfolien in einer Stärke 

von teilweise weniger als 6/1.000 

mm für Lebensmittelverpackungen. 

Das filigrane Material wird auf Folienrollen 

von bis zu 17 Tonnen Gewicht 

gewickelt, die es anschließend innerbetrieblich 

zu transportieren gilt. 

Den reibungslosen Materialfluss 

reguliert ein Intralogistiksystem. 

Mit Hilfe eines Tunnelshuttles und 

mehrerer Coiltransportwagen 

werden die verschiedenenWalzwerkbereichevollautomatisch 

vernetzt. Die Automation 

der Anlage hat 

die Aberle Automation, 

Leingarten, realisiert. 

Generalunternehmer 

war die Firma Vollert 

Anlagenbau mit Sitz in 

Weinsberg. 

Herzstück der Intralogistik 

ist ein automatisiertesHochregallager. 

Mit 160 Metern 

Länge, zehn Metern 

Breite und 30 Metern 

Höhe bietet es Platz für 

800 Aluminiumcoils. 

Es dient gleichzeitig als 

Produktions- und Weiterverarbeitungspuffer. 

Zwei Regalbediengeräte 

übernehmen das Ein- 

und Auslagern der Coils. 

32 Antriebsachsen in 

Fahr-, Hub- und Teleskopwerken halten 

sie mit einer Leistung zwischen 5 

und 200 Kilowatt in Bewegung. Dahinter 

stecken SEW-Umrichter der 

neuen Baureihe 7 von Movidrive 

B mit IPOS-Positioniertechnologie, 

die in dieser Applikation Premiere 

feiert. Die Ansteuerung und Auswertung 

der Baugruppe erfolgt über 

Profinet, die Positionierung mittels 

Absolutwertgeber. Aberle Materialfluss- 

und Warehouse-Managementsysteme 

stellen die Integration der 

Regalbediengeräte in die Intralogistik 

sowie deren Überwachung sicher. 

Das Materialflusssystem „Aberle 

PMS-M“ sorgt für die reibungslosen 

Abläufe aller Fördertechnikprozesse. 

Es verwaltet die Abläufe und sorgt 

für einen effizienten Warenfluss. Das 

Lagerverwaltungssystem „Aberle 

PMS-W“ gewährleistet eine komfortable 

Verwaltung von Artikeln und 

Aufträgen und steuert unterschiedliche 

Lagerbereiche wie Wareneingang 

und Warenausgang, Kommissi- 

Hochregallager bei Xiamen Xiashun Aluminium Foil 

onierung und Versand. 

Die komplette PMS-Reihe besteht 

aus einem fünfteiligen System, mit 

dem alle Bereiche der Logistikkette 

vom Materialfluss über die Disposition 

von Robotern bis zur Visualisierung 

abgedeckt werden können. 

Die Herausforderung bestand darin, 

das Lager mit einer Kapazität von 

rund 14.000 Tonnen Aluminiumfolie 

gegen mögliche Erdstöße der Stärke 5 

bis 6 auf der Richterskala zu sichern. 

Die Statik entstand in enger Abstimmung 

mit dem zuständigen chinesischen 

Staatsinstitut. So entstand ein 

Gebäude, das in der Querachse Bewegungen 

von fast zehn Zentimetern 

verkraftet. Damit können auch die 

Regalbediengeräte sicher und präzise 

ihre Strecken fahren. 

Aberle Automation ist Aussteller 

auf der ALUMINIUM 2010. Hall 1, 

Stand G76. 

Vollert Anlagenbau ist Aussteller 

auf der ALUMINIUM 2010. Hall 1, 

Stand F35. 


Vollert

luoyang longding Alu orders process automation 

systems for aluminium rolling lines from Siemens 

Siemens Limited China has 

received an order from Luoyang 

Longding Alu to supply 

26 Siroll ALU TCS process 

automation systems for its 

new aluminium rolling mill. 

The value of this order lies in 

the doubledigit million US 

dollar range. The project is 

scheduled to be completed in 

September 2011. 

The Siemens systems will be installed 

on cold and foil rolling 

stands in the new rolling mill. 

This is the first time that Siroll 

Heavy Duty Shapemeters will 

be used for the online flatness 

measurement of cold strip ranging 

between 0.05 and 5.5 mm in 

thickness. Integrated Automatic 

Trend Alignment (ATA) guarantees 

precise positioning of 

the measuring roller under all 

operating conditions. Even at 

slow rolling speeds, the Heavy Duty 

Shapemeter returns continuous, highresolution 

data on the flatness of the 

strip being measured. 

The Siroll ALU TCS process automation 

system is based on the 

proven Simatic TDC platform and 

will optimise the production flow 

and improve the quality of the end 

products. The system contains, for 

example, components for automatic 

roll gap control and roll eccentricity 

compensation to meet these targets. 

Flatness is measured not only by the 

Heavy Duty Shapemeters but also by 

Halle 3, 

Stand I50 



The Siroll ALU TCS operator control and monitoring interface keeps all the aluminium rolling 

stand parameters in view all the time 

further 22 Siroll Air Bearing Shapemeters, 

which can measure cold strip 

ranging in thickness from 0.005 to 4 

mm. There will soon be over 500 of 

these flatness measurement systems 

in use throughout the world. Siemens 

is also supplying 26 Siroll ISV (Integrated 

Solenoid Valve) spraying systems 

for zone cooling and lubricating 

the rolling stands. The company will 

be responsible for installing and commissioning 

all the systems and also 

undertake the customer training. 

The controlling interest in Luoyang 

Longding Alu is held by the Dingsheng 

Industry group, based in Hangzhou, 

Zhejiang Province. This group of 

companies currently operates three 

locations with a total annual production 

of more than 150,000 tonnes of 

rolled aluminium products for use 

especially in the domestic goods, 

electronics and packaging industries. 

The new aluminium rolling mill in 

Luoyang, Henan Province, will increase 

the annual production capacity 

to around 300,000 tonnes. 

Siemens VAI is an exhibitor at ALU- 

MINIUM 2010. Hall 3, Stand J18. 

Hochleistungsanlagen in der Wärmebehandlung 

www.schwartz-wba.de 

Innovative und hocheffiziente Erwärmungskonzepte 

mit Wärmerückgewinnung. 

Individuell konzipierte Anlagen mit hoher 

Verfahrenssicherheit und Wirtschaftlichkeit! 

schwartz GmbH 

Edisonstraße 5 

D-52152 Simmerath 

� + 49 ( 0 ) 24 73/94 88-0 

info@schwartz-wba.de 

35 

Siemens VAI


Weiterentwickelte laufbahnbeschichtung 

reduziert Reibung und gewicht 

Zur Reduzierung der CO 2 -Emissionen 

setzt die KS Aluminium- 

Technologie GmbH (KS Atag) bei 

der Zylinderlaufbahn ein neuartiges 

Beschichtungsverfahren mit 

mechanischem Aufrauen in Form 

eines Schwalbenschwanzprofils 

ein, das seit seiner Einführung 

2009 weiterentwickelt wurde. 

Erste beschichtete Prototypen befinden 

sich inzwischen bei einem 

großen OEM in der Erprobung; bei 

einem weiteren Hersteller werden 

Prototypen- und Serienentwicklungen 

geplant. Der Serienstart 

mit beiden Automobilherstellern 

ist für 2013 vorgesehen. 

Tribologisch gesehen entfallen etwa 

fünfzig Prozent der Gesamtreibung 

im Verbrennungsmotor auf Zylinderlaufbahn, 

Kolben und das Kolbenringpaket. 

Insbesondere die Zylinderlaufbahn 

kann einen wesentlichen 

Beitrag zur Verringerung von 

Verbrauch und Emissionen sowie 

zur Verbesserung des mechanischen 

Wirkungsgrades leisten. Um diesen 

Effekt optimal auszunutzen, können 

Aluminiumlaufbahnen durch thermisches 

Spritzen mit einer verschleißfesten 

und tribologisch 

günstigen Schicht versehen 

werden, die nachweislich die 

Reibung reduziert. Technisch 

gesehen wird dabei eine dünne 

Eisenschicht in die Zylinderbohrung 

eingebracht. 

Um eine gute Verbindung zwischen 

Aluminiumgrundwerkstoff 

und Eisenschicht sowie eine optimale 

Haftung zu gewährleisten, ist eine 

Aufrauung mittels mechanischer Bearbeitung 

notwendig. Hierbei konnten 

die Standzeiten der Werkzeuge 

deutlich erhöht und damit Kosten eingespart 

werden. Eine Alternative zur 

Aufrauung wäre das Hochdruckwasserstrahlen, 

doch bietet die mechanische 

Bearbeitung monetäre und anlagenspezifische 

Vorteile. So können 

anstatt einer komplexen Hochdruckpumpentechnologie 

mit anschließender 

Wasseraufbereitung einfache 

improved cylinder lining 

coating reduces friction and weight 

To reduce CO 2 emissions, KS Aluminium-Technologie 

(KS Atag) is 

using a new type of coating process 

for cylinder lining surfaces, 

with mechanical roughening in the 

form of a dovetail profile, which 

since its introduction in 2009 has 

been developed further. Meanwhile 

the first coated prototypes 

are being tested by a major OEM; 

at another manufacturer prototypes 

and series developments 

are planned. The start of series 

production is scheduled at both 

these automobile manufacturers 

for 2013. 

From the tribological standpoint approximately 

fifty percent of the total 

friction in internal combustion engines 

can be attributed 

to the cylinder 

Pkw-Getriebegehäuse. Demnächst startet die Serienproduktion 

eines Nkw-Getriebegehäuses im Niederdruckguss. 

Transmission housing for a passenger car. Soon, the mass 

production of transmission housings for utility vehicles by 

low-pressure casting will begin. Photo: Kolbenschmidt 

lining surface, the piston and the piston-ring 

assembly. The cylinder lining 

surface in particular can contribute 

substantially towards improving 

mechanical efficiency. To make the 

most of this effect, aluminium cylinder 

liners can be provided by thermal 

spraying with a wear-resistant 

and tribologically favourable layer, 

which demonstrably reduces friction. 

In technical terms a thin layer of iron 

is applied in the cylinder bore. 

To ensure a good bond between 

the aluminium basis material and the 

iron layer, with optimum adhesion, 

roughening by mechanical machining 

is needed. An alternative to roughening 

would be high-pressure water-jet 

treatment, but mechanical machining 

has monetary and plant-specific 

advantages. Instead of complex 

high-pressure pump technology and 

subsequent water treatment, simple 

machining centres can be used. The 

sprayed layer is then honed to produce 

a tribologically suitable piston 

running surface; for this, the honing 

process must be adapted individually 

for the cylinder 

crankcase and its 

coating. 

As the liner material 

in aluminium 

cylinder crankcases, 

grey cast iron is the 

material used conventionally. 

Besides 

relatively high weight 

this has a whole series 

of other technical disadvantages. 

For example, 

the different thermal 

expansion of grey cast 

iron and aluminium results 

in undesirable cylinder 

distortion and local heat 

transfer problems can occur 

if an air gap forms between 

the lining and the 

aluminium casing. With 

the new type of lining surface it is now 

possible to replace the conventional 

grey iron in the lining area, and so to 

save considerable weight. 


new challenges 

for heavy-duty applications 

The company has broken into the utility 

vehicle market sector with the development 

of a transmission housing 

produced by low-pressure diecasting, 

for heavy-duty trucks. The prototype 

phase is scheduled for this year, while 

series production should begin from 

the end of 2011. 

A market study confirms the general 

potential for the use of aluminium 

castings by utility vehicle manufacturers 

in the structural and chassis 

areas. Owing to the severe demands 

arising from daily loading and with 

regard to the lifetime required in the 

sector of utility vehicles, it is to be 

assumed that depending on product 

design, production run size and the 

respective performance specification, 

the appropriate production method 

will be die- or sand-casting with gravity 

or low-pressure filling. 


Spouts and 

Stoppers 

Bearbeitungszentren zum Einsatz 

gebracht werden. Anschließend wird 

die aufgespritzte Schicht mittels Honen 

zu einer tribologisch geeigneten 

Kolbenlaufbahn bearbeitet, wobei das 

Honverfahren individuell auf das Zylinderkurbelgehäuse 

und dessen Beschichtung 

angepasst werden muss. 

Als Buchsenmaterial in Aluminium-Zylinderkurbelgehäusen 

wird 

herkömmlicherweise Grauguss verwendet. 

Dieser hat jedoch neben 

einem relativ hohen Gewicht eine 

ganze Reihe weiterer technischer 

Nachteile. So führt die unterschiedliche 

Wärmeausdehnung von Grauguss 

und Aluminium zu einer ungünstigen 

Zylinderverformung sowie zu 

lokalen Wärmeübergangsproblemen, 

wenn sich ein Luftspalt zwischen 

Buchse und Aluminiumgehäuse bildet. 

Mit der neuartigen Laufschicht 

ist es nun möglich, den Grauguss im 

Buchsenbereich zu ersetzen und somit 

deutlich Gewicht einzusparen. 


neue herausforderungen 

bei heavy-Duty 

Der Markteintritt in den Nkw-Sektor 

ist dem Unternehmen mit der Entwicklung 

eines Getriebegehäuses im 

Niederdruck-Kokillenguss für schwer 

beanspruchte Lastkraftwagen gelungen. 

Die Prototypenphase soll noch 

dieses Jahr stattfinden, die Serienproduktion 

Ende 2011 starten. 

Eine Marktstudie belegt das generelle 

Potenzial für den Einsatz 

von Aluminiumgussteilen bei Nkw- 

Herstellern im Struktur- und Fahrwerksbereich. 

Aufgrund der hohen 

Anforderungen infolge der täglichen 

Belastungen sowie der geforderten 

Lebensdauer im Nkw-Bereich ist davon 

auszugehen, dass abhängig von 

Produktdesign, Stückzahlen und dem 

jeweiligen Lastenheft der Kokillenoder 

Sandguss mit Schwerkraft- oder 

Niederdruckfüllung das geeignete 

Produktionsverfahren sein wird. 

■ ■ 

for Aluminium DC 

casting 

Drache 

u m w e l t t e c h n i k 

Ceramic Foam 

Filters 

for Aluminium DC 

casting 

Drache Umwelttechnik GmbH · mail@drache-gmbh.de · www.drache-gmbh.de 

37


Ein Ansatz zur Steigerung der Stromausbeute 

Aufbereitung von Abdeckmaterial aus elektrolysezellen 

Die Aluminiumelektrolyse ist 

bekanntlich ein energieintensiver 

Prozess und Strom inzwischen 

eine teure Energie, jedenfalls in 

Europa. Schon aus betriebswirtschaftlichen 

Gründen hat die Industrie 

daher in den vergangenen 

Jahrzehnten kontinuierlich daran 

gearbeitet, den Stromeinsatz immer 

weiter abzusenken. Prozesstechnische 

Quantensprünge, mit 

denen die Stromausbeute weiter 

hochgeschraubt werden kann, sind 

kaum zu erwarten. Daher, oder gerade 

deshalb, gilt es, jeden Aspekt 

auszuloten, der die Produktivität 

im Hüttenprozess verbessert. Ein 

Ansatzpunkt dazu kommt von der 

Firma Steinert Elektromagnetbau 

aus Köln. Sie hat in Versuchen 

mit einem großen Aluminiumproduzenten 

ein Konzept zur Aufbereitung 

und Kreislaufführung 

des Anodenabdeckmaterials in 

Elektrolysezellen entwickelt, das 

darauf zielt, die Verunreinigungen 

dieses Abdeckmaterials zu verringern 

und die Metallqualität und 

Stromausbeute dadurch weiter zu 

steigern. 

Bei der Schmelzflusselektrolyse von 

Aluminium erstarrt das Elektrolytmaterial 

nach dem Anodenwechsel um 

die Anode und bildet eine feste Kruste 

aus Kryolith, Aluminiumfluorid, 

Aluminiumoxid und Kalziumfluorid. 

Darauf wird in einem weiteren Arbeitsschritt 

das Anodenabdeckmaterial 

aufgebracht, was eine Oxidation 

der heißen Anoden verhindern soll. 

Außerdem verringert das Abdeckmaterial 

Wärmeverluste über den Anodenbereich. 

Mit der Zeit kommt es jedoch zu 

Verunreinigungen dieses Abdeckmaterials 

mit Stoffen, die ebenfalls im 

Elektrolyseprozess genutzt werden: 

Die Kruste reichert sich mit Kohlenstoff, 

Eisenpartikeln (von den Gusshülsen 

zur Befestigung der Anodennippel 

an der Kohle) und Aluminium 

an, sodass in den Ofen fallendes Abdeckmaterial 

die Metallqualität verunreinigt 

und die Kohlerückstände 

An approach toward increasing current yield 

treatment of cover material 

from electrolysis pots 

Prinzipschema des Wirbelstromabscheiders mit exzentrischem Polsystem 

Diagram showing the principle of an eddy current separator with eccentric pole system 

Aluminium electrolysis is of 

course an energy-intensive process 

and electricity is now an 

expensive form of energy, at any 

rate in Europe. Thus, for reasons 

of operational economics alone 

the industry has striven continually 

over the past decades to keep 

reducing its power consumption. 

Quantum leaps in process technology, 

with which current yields can 

be boosted still further, are now 

hardly likely any longer. Accordingly, 

or rather precisely for that 

reason, it is necessary to make the 

most of every possible other aspect 

that can improve productivity 

in the smelting process. One approach 

to this comes from Steinert 

Elektromagnetbau in Germany. In 

tests carried out jointly with a major 

aluminium producer Steinert 

has developed a concept for the 

treatment and recycling of the anode 

cover material in electrolysis 

pots, whose aim is to reduce the 

contamination of this cover material 

and thereby to improve the 

metal quality and current yield 

still more. 

In the fused-salt electrolysis of aluminium 

the electrolyte material solidifies 

around the anodes when they 

are changed, forming a solid crust of 

cryolite, aluminium fluoride, alumina 

and calcium fluoride. In a subsequent 

working step an anode cover material 

is applied, which is intended to 

prevent oxidation of the hot anodes. 

The cover material also reduces heat 

losses from the anode area. Over time, 

however, this cover material becomes 

contaminated with substances that are 

also used in the electrolysis process: 

the crust is enriched in carbon, iron 

particles (from the casting sleeves for 

attaching the anode nipples to the carbon) 

and aluminium, so that any cover 

material that falls off into the furnace 

contaminates the metal, and carbon 

residues reduce the current yield of 

the process, which nowadays ranges 

from 93 to 95 percent. 

To reduce the contamination of the 

cover material as much as possible, 

various steps for removing it have to 

be carried out. For this the contaminated 

material is crushed, the coarsegrained 

fraction is separated out in a 

multi-step sieving unit, and the finegrained 

fraction is returned directly 

for electrolysis. In the preparation 

process many aluminium smelters 

use eddy current separators to separate 

out free aluminium droplets 

present in the material. Sometimes 

optical sorting equipment is also used 

to separate the black carbon from the 

white crust material. 

Overall, however, this treatment 

is only carried out with a view to 

the main contaminants and does not 

capture them all. The recovery of 


Fotos & Grafiken: Steinert

aluminium is incomplete since most 

eddy current separators do not operate 

with an eccentric pole system 

and in addition composites containing 

aluminium and electrolyte are 

difficult to recognise. Optical sorting 

methods too only help to a limited 

extent because the ‘colour spectrum’ 

of the material being sorted ranges in 

practice from white, through every 

shade of grey, to black, so that optical 

sorting only works up to a point. The 

treated cover material nowadays fed 

back into the process is still relatively 

highly contaminated. 

In tests carried out jointly with 

one of the major aluminium producers 

Steinert has developed a concept 

with which the cover material is prepared 

more effectively overall and its 

contaminants are reduced almost to 

zero. An advantage for the development 

work was that Steinert already 

offers every sorting technology, from 

magnet drum separators to sensor-assisted 

sorting methods. 

The essential approach of the concept 

is to prepare the material so that 

no composite materials such as alumina 

with aluminium remain behind 

in the recycled material. 

This can 

be achieved 

Schema des Induktionssortiersystems 

ISS 

Diagram of the induction 

sorting system ISS 

by induction sorting, which in contrast 

to optical sorting does not rely 

on secondary characteristics such as 

colour as separation criteria but, rather, 

directly measures the electrical 

conductivity of every particle in the 

sorting material flow and separates 

out conductive material by means of 

compressed-air pulses. 

The advantage of induction sorting 

is that it not only recognises electrolyte-with-aluminium 

composites very 

effectively, but also oxide materials 

➝ 


die Stromausbeute im Prozess, die 

heute zwischen 93 und 95 Prozent 

liegt, verringern. 

Um die Verunreinigung des Abdeckmaterials 

möglichst gering zu 

halten, müssen unterschiedliche 

Schritte zu ihrer Ausschleusung 

durchgeführt werden. Dazu wird das 

verunreinigte Material zerkleinert, 

das Grobkorn über eine mehrstufige 

Siebanlage abgesiebt, während das 

Feinkorn direkt in die Elektrolyse zurückgeführt 

wird. In dem Aufbereitungsprozess 

werden von manchen 

Aluminiumhütten Wirbelstromabscheider 

eingesetzt, um im Material 

enthaltene freie Aluminiumtropfen 

abzutrennen. Partiell kommen auch 

Farbsortiergeräte zum Einsatz, um 

den schwarzen Kohlenstoff von weißem 

Krustenmaterial zu trennen. 

Insgesamt wird diese Aufbereitung 

jedoch nur schwerpunktmäßig 

durchgeführt und umfasst nicht alle 

Verunreinigungen. Die Aluminiumrückgewinnung 

ist unvollständig, da 

die meisten Wirbelstromabscheider 

ohne ein exzentrisches Polsystem arbeiten 

und noch dazu Verbundmaterialien 

aus Aluminium und Elektrolyt 

nur schwer erkannt werden. Auch 

Farbsortieranlagen helfen nur eingeschränkt 

weiter, weil das 

„Farbspektrum“ des 

Sortiermaterials in 

der Praxis von weiß 

über alle möglichen 

Graustufen bis hin 

zu schwarz reicht, 

sodass eine Farbsortierung 

nur eingeschränktfunktioniert. 

Das heutzutage 

aufbereitete 

Abdeckmaterial, das in den 

Prozess zurückgeführt wird, weist 

weiterhin eine relativ hohe Verunreinigung 

auf. 

Steinert Elektromagnetbau hat in 

Versuchen mit einem der großen Aluminiumproduzenten 

ein Konzept entwickelt, 

mit dem das Abdeckmaterial 

insgesamt besser aufbereitet und seine 

Verunreinigungen auf nahezu Null 

abgesenkt werden. Vorteilhaft bei der 

Entwicklung war, dass Steinert alle 

Sortiertechnologien von der Magnetscheidung 

bis zur sensorgestützten 

Sortierung herstellt. 


Der wesentliche Ansatzpunkt des 

Konzeptes ist, das Material so aufzubereiten, 

dass keine Materialverbunde, 

zum Beispiel von Tonerde 

und Aluminium, im Kreislaufmaterial 

zurückbleiben. Dies kann über eine 

induktive Sortierung erreicht werden, 

die im Gegensatz zur Farbsortierung 

nicht sekundäre Merkmale wie die 

Farbe als Ausschleusungskriterium 

heranzieht, sondern direkt die elektrische 

Leitfähigkeit jedes Partikels 

im Sortierstrom misst und leitendes 

Material über Druckluftstöße aussortiert. 

Der Vorteil der Induktionssortierung 

besteht darin, dass sie nicht nur 

Verbunde aus Elektrolyt und Aluminium 

gut erkennt, sondern auch 

Oxidmaterial, das mit Eisenpartikeln 

versetzt ist. Sogar der Kohlenstoff 

wird als einzelnes Partikel oder im 

Verbund erkannt und ausgeschleust. 

Das Induktionssortiersystem (ISS) hat 

sehr empfindliche, schmale Sensoren 

mit 12,5 mm Spurbreite, durch die 

in der Regel auch kleine elektrisch 

leitende Partikel um die 2 mm erkannt 

werden. Insgesamt lässt sich 

der Kreislauf betrieblich eingesetzter 

Stoffe auf diese Weise weiter schließen 

und die Deponierung von Material 

reduzieren. 

Ulrich Kohaupt, Leiter Geschäftsfeldentwicklung 

bei Steinert, dazu: 

„Die von uns durchgeführten Versuche 

haben die Funktionsfähigkeit 

unseres Induktionssortiersystems ISS 

nicht nur für die Metalle, sondern 

auch für die Kohlenstoffverbunde 

mit guten Ergebnissen bestätigt. Mit 

dem gewählten Sortieransatz können 

wir sehr reines Abdeckmaterial zurückgewinnen, 

das anschließend zerkleinert 

und in den Prozess zurückgeführt 

wird. Auf diese Weise kann 

die Stromausbeute in der Elektrolyse 

zwischen 0,1 und 0,3 Prozentpunkten 

und die Metallqualität um 1,3 ppm 

im Eisenanteil verbessert und damit 

ein wesentlicher Kostenfaktor im 

Hüttenprozess, der Stromverbrauch, 

reduziert werden.“ Wie Kohaupt weiter 

erläutert, wird das Induktionssortiersystem 

seit rund zehn Jahren in 

der ebenfalls rauen Umgebung der 

Schrottwirtschaft mit großem Erfolg 

eingesetzt. Es laufen weltweit rund 

200 Geräte. 

mixed with iron particles. Even ➝ 

39


Der gesamte Aufbereitungsprozess 

umfasst die Stufen Siebrost zur Vermeidung 

von Überkorn, staubarmes 

Brechen/Zerkleinern, Siebung, Magnetscheidung, 

Wirbelstromscheidung, 

Induktionssortierung. Der Siebüberlauf 

wird dem Brecher zurückgeführt. 

Hier können durch einen Wirbelstromscheider 

auch über 20 cm große 

A l u m i n i u m t e i l e 

abgeschieden werden. 

Das gereinigte 

Material, das nach 

diesem stufenweisen 

Prozess übrig 

bleibt, wird abschließend 

weiter 

zur Endfeinheit zermahlen 

und in den 

Elektrolyseprozess 

zurückgeführt. Das 

vom ISS aussortierte 

Material wird 

weiter aufgeschlossen 

und nochmals 

über eine sehr 

starke Permanentmagnettrommel 

geführt, mit der auch 

schwach magnetisches Material erfasst 

wird. Anschließend gewinnt ein 

Feinkorn-Wirbelstromabscheider das 

freigelegte Aluminium zurück. 

Exakte Berechnungen zur Kosteneinsparung 

liegen derzeit nicht vor, 

aber die wirtschaftlichen Vorteile 

einer optimierten Aufbereitung des 

Abdeckmaterials liegen auf der Hand. 

Schließlich geht es um beachtliche 

Strom- und Sortiermengen, denn zur 

Produktion einer Tonne Aluminium 

muss rund eine halbe Tonne Abdeckmaterial 

im Kreislauf geführt werden. 

Das kann sich, je nach Betriebsgröße, 

zu mehreren Hunderttausend Tonnen 

im Jahr summieren. 

Eine grobe überschlägige Rech- 

nung unter restriktiven Annahmen 

hinsichtlich des Stromverbrauchs 

(13 kWh/kg Al), eines Strompreises 

von 3 Eurocent je kWh in Europa 

und einer 0,2%igen Verbesserung 

des Wirkungsgrades ergibt bei einer 

Jahresproduktion von 300.000 Tonnen 

eine Kostenersparnis von mehr 

als 230.000 Euro. Das Investment in 

Mit dem Induktionssortiersystem ISS abgetrennter Kohlenstoff 

Carbon separated off by the induction sorting system ISS 

die entsprechenden Sortieranlagen 

einschließlich Brecher und Siebmaschine 

wäre nach ein bis zwei Jahren 

amortisiert. Weitere wirtschaftliche 

Vorteile ergeben sich aus der verbesserten 

Aluminiumqualität und die 

weiter gesteigerte Betriebssicherheit 

durch die konstant hohe Qualität des 

Abdeckmaterials. 

Steinert geht bei dieser Lösung 

einen Schritt auf die betreibende 

Großindustrie zu und liefert zusammen 

mit erfahrenen Unterlieferanten 

auch den Gesamtprozess, bestehend 

aus Brechern, Sieben, Förderern und 

Sortiermaschinen. 

Steinert Elektromagnetbau ist 

Aussteller auf der ALUMINIUM 

2010. Halle 7, Stand B01. 

Mit dem Wirbelstromscheider abgetrenntes grobes (links) und feines (rechts) Aluminium 

Coarse-grained (left) and fine-grained (right) aluminium fraction separated off by the 

eddy current separator 

carbon is recognised as an individual 

particle or in combination, and is removed. 

The induction sorting system 

(ISS) has very sensitive, narrow sensors 

with a track width of 12.5 mm by 

which, as a rule, even small electrically 

conductive particles of the order 

of 2 mm are recognised. Overall, the 

cycle of materials used in the process 

can be closed more effectively in 

this way and the quantity of material 

dumped is reduced. 

Ulrich Kohaupt, director of New 

Business / Marketing at Steinert, says: 

“The tests we carried out demonstrated 

the functionality of our ISS 

induction sorting system not only for 

metals but also for carbon composites, 

with good results. With the sorting approach 

adopted we can recover very 

pure cover material, which is then 

crushed and returned to the process. 

In this way the electrolysis current 

yield can be improved by between 

0.1 and 0.3 percent and the quality of 

the metal by 1.3 ppm of iron fraction 

so that the power consumption, an 

important cost factor in the smelting 

process, is reduced.” As Mr Kohaupt 

also explains, the induction sorting 

system has been used for about a decade 

in the also harsh environment of 

the scrap economy, with great success. 

About 200 units are now operating 

worldwide. 

The treatment process as a whole 

involves the steps of riddling through 

a mesh to avoid oversize grains, lowdust 

crushing/comminution, sieving, 

magnet drum separation, eddy current 

separation and induction sorting. 

Sieving rejects are returned to 

the crusher. Here, aluminium pieces 

even larger than 20 cm can be separated 

by an eddy current separator. 

The purified material left over after 

this stepwise procedure is then milled 

to its final degree of refinement and 

fed back into the electrolysis process. 

The material separated out by the ISS 

is crushed further and then passes 

through a very powerful permanent 

magnet drum by which even weakly 

magnetic material is captured. Finally, 

a fine-grain eddy current separator 

recovers the aluminium released. 

At present no exact calculations 

on the cost savings are available, but 

the economic advantages of optimal- 


ly prepared cover material should 

be obvious. Ultimately, considerably 

current and sorting material quantities 

are involved, since to produce 

one tonne of aluminium approximately 

half a tonne of cover material 

must go through the cycle. Depend 

ing on the size of the operation, that 

can add up to many hundreds of 

thousands of tonnes per year. 

A rough calculation based on 

restrictive assumptions regarding 


current consumption (13 kWh/kg 

of aluminium), an energy price of 3 

eurocents per kWh in Europe and a 

0.2% improvement of the efficiency 

gives, for an annual production of 

300,000 tonnes, a cost saving of more 

than 230,000 euros. The investment in 

the corresponding sorting equipment, 

including the crusher and sieving machines, 

would be recouped in one to 

two years. Other economic advantages 

result from the improved quality of 


the aluminium and the greater operational 

reliability due to the constant 

high quality of the cover material. 

With this system Steinert has taken 

a step towards largescale productive 

industry and, backed by experienced 

subcontractors, supplies the entire 

process consisting of crushers, sieves, 

conveyors and sorting machines. 

Maßgeschneiderte lösungen zur 

energie- und Datenübertragung in Aluminiumhütten 

tailor-made solutions for energy and 

data transmission in aluminium smelters 

Contrary to clean-room technology, 

in aluminium smelters one 

is faced with dust, vapours and 

gases. High temperatures – sometimes 

over 85°C – along with a 

carbon-laden atmosphere and 

high air humidity are the order 

of the day in the production potrooms. 

Normally, the smelters 

operate 24 hours a day, 365 days 

a year. These severe conditions 

make special demands on energy 

and data transmission. 

ConductixWampfler AG, a worldleading 

manufacturer of systems for 

energy and data transmission to mobile 

consumers, has for more than 30 

years been developing tailormade 

solidifications for the aluminium 

industry. Already in 1997 the then 

Wampfler AG patented a current 

conductor rail specially developed 

for the aluminium sector and brought 

it to market. “We well understand the 

special challenges faced by the sector 

and have in the past continually 

reacted to production changes with 

new solutions”, explains Dieter Seidel 

of ConductixWampfler (global 

product manager Conductor Rails). 

Most recently the company, located 

in Weil on the Rhine, has equipped 

the Dubal, Soha Aluminium, Egyptalum 

and Aluminium Bahrain smelters 

with modern energy and data ➝ 

Images: Conductix-Wampfler 

transmission systems. 

At present ConductixWampfler is 

implementing a prestige project for 

Emirates Aluminium (Emal) in the 

United Arab Emirates. The USD5.7 

billion industrial project is the largest 

in the UAR apart from the oil and 

gas industry. 750,000 tonnes of aluminium 

per year will be produced 

locally from April 2010 when the 

first construction phase is completed; 

after the completion of the second 

phase aluminium production will almost 

double to 1.4 million tonnes. 

The sheer size of the smelter raises 

formidable challenges for energy and 

data transmission. Each of the four potrooms 

is 1.3 km in length. Over that 

distance move the process cranes, 

the sotermed pot tending machines 

(PTMs) for replacing the anodes. At 

present four potrooms are already in 

operation. In 

Schleifleitungssystem 

Program 0813, 3-polig 

Conductor rail system, type 0813, 3-pole 

Steinert Elektromagnetbau is an 

exhibitor at ALUMINIUM 2010. 

Hall 7, Stand B01. 

Anders als in der Reinraumtechnik 

ist man in Aluminiumhütten 

mit Staub, Dämpfen und Gasen 

konfrontiert. Hohe Temperaturen 

mit teilweise mehr als 85 °C, eine 

kohlehaltige Atmosphäre und eine 

hohe Luftfeuchtigkeit sind in den 

Produktionshallen an der Tagesordnung. 

Normalerweise laufen 

die Anlagen in den weitläufigen 

Elektrolysehallen 365 Tage im 

Jahr rund um die Uhr. Diese harten 

Rahmenbedingungen stellen 

besondere Anforderungen an die 

Energie- und Datenübertragung. 

Die ConductixWampfler AG, weltweit 

ein führender Hersteller von 

Systemen für die Energie und Datenübertragung 

zu beweglichen Verbrauchern, 

entwickelt seit über 30 Jahren 

maßgeschneiderte Lösungen für die 

Aluminiumindustrie. Bereits 1997 hat 

die damalige Wampfler AG eine speziell 

für die Branche entwickelte 

Schleifleitung patentieren lassen und 

auf den Markt gebracht. „Wir kennen 

die besonderen Herausforderungen 

der Branche sehr gut und haben in 

der Vergangenheit kontinuierlich mit 

neuen Lösungen auf die Veränderungen 

in der Produktion reagiert“, 

erklärt Dieter Seidel von Conductix 

Wampfler (Global Product Manager 

Conductor Rails). Zuletzt hat das Unternehmen 

aus Weil am Rhein Aluminiumhütten 

für Dubal, Soha Aluminium, 

Ägyptalum und Aluminium 

Bahrein mit moderner Energie und 

Datenübertragung ausgerüstet. ➝ 

41


Schleifleitungssystem Program 0812 

Conductor rail system, type 0812 

Aktuell realisiert Conductix-Wampfler 

ein Prestigeprojekt für Emirates 

Aluminium (Emal) in den Vereinigten 

Arabischen Emiraten. Das 5,7 Mrd. 

Dollar teure Vorhaben ist das bisher 

größte einzelne Aluminiumwerk 

weltweit und das größte Industrieprojekt 

der Vereinigten Arabischen 

Emirate außerhalb der Öl- und Gasindustrie. 

750.000 Jahrestonnen Aluminium 

sollen nach Abschluss der 

ersten Bauphase ab April 2010 vor 

Ort produziert werden. Nach Abschluss 

der zweiten Phase soll die 

Aluminiumproduktion auf 1,4 Mio. 

Tonnen verdoppelt werden. 

Die schiere Größe der Anlage stellt 

auch die Energie- und Datenübertragung 

vor große Herausforderungen. 

Jede der vier Elektrolysehallen ist 

1,3 Kilometer lang. Über diese Länge 

verlaufen die Prozesskräne, die 

sogenannten Pot Tending Machines 

(PTM) zum Wechseln der Anoden. 

Zurzeit sind bereits vier Hallen in Betrieb. 

Jeweils zwei Hallen bilden eine 

Elektrolyselinie. Auf jeder Kranbahn 

sind vier bis fünf Kräne im Einsatz. 

Diese lassen sich auf einer Querachse 

etwa in der Mitte der Kranbahnen von 

einer Linie auf die andere umsetzen. 

Um eine ununterbrochene Energiezufuhr 

auch während des Umsetzvorgangs 

zu erreichen, werden spezielle 

Transferstücke mit Ein- und 

Ausfahrstücken eingesetzt. 

Die ungewöhnlich große Länge 

der Kranbahn erfordert auch wegen 

der großen Temperaturunterschiede, 

dass die Längenausdehnungsstücke 

der einzelnen Stromschienen robust 

und zuverlässig sind. Die Dehnstücke 

übernehmen die Aufgabe, die in den 

Gebäuden auftretenden Ausdehnungen 

auszugleichen. Besondere 

Anforderungen stellt auch die Aufhängung 

der Schleifleitungen: Sie 

muss zum einen sehr robust und stabil 

ausgeführt sein und zum anderen 

eine ungehinderte Ausdehnung des 

Schleifleitungsprofils zulassen. 

„Für die Energie- und Datenübertragung 

zu den PTM’s setzen wir überwiegend 

einzelpolige, isolierte Aluminium-Schleifleitungen 

vom Typ 813 

mit 1.000 Ampère Nennstrom ein“, 

erklärt Seidel. Besonders die extrem 

langen Verfahrwege der Kräne in den 

Elektrolysehallen und deren Bedarf 

an hohen Strömen zum Anlaufen 

seien entscheidend für die richtige 

Auswahl gewesen. Die Kombination 

von Aluminium und Edelstahl bietet 

eine kostenoptimierte Lösung für 

diese spezielle Anwendung. Durch 

detailliertes und projektspezifisches 

Engineering werden die Systeme optimiert, 

um den hohen Energiebedarf 

auch bei einem Stillstand der PTM’s 

optimal zu gewährleisten. 

Durch den modularen Aufbau der 

Schleifleitungsproduktpalette lassen 

sich kurze Kranlinien oder geänderte 

Strombedarfe durch kleinere Querschnitte 

(ab 500 A) oder durch die 

kleinere Baureihe 0812 kostenoptimiert 

realisieren. Die Komponenten 

sind standarisiert und können auch 

von weniger erfahrenen Installationsfirmen 

nach kurzer Zeit effizient und 

kostengünstig installiert werden. 

Wichtig: die richtige isolierung 

„Die in der Aluminiumproduktion üblichen 

Gase, Dämpfe und der Staub 

sowie die hohen Temperaturen erfordern 

eine hitzebeständige Isolierung 

der Schleifleitungen“, betont Herman 

Thoma, Projektingenieur für Prozesskrane 

bei Conductix-Wampfler. Im 

Bereich der Anodenfertigung ist die 

Atmosphäre zudem sehr kohlehaltig 

und feucht, was die Gefahr von Spannungsüberschlägen 

erhöht. „Hier 

setzen wir spezielle Isolatoren zur 

Sicherheit ein“, so Thoma. 

Der Isolierwerkstoff ermöglicht 

eine höhere zulässige Betriebstemperatur 

der Schleifleitungsanlage, die 

optimal auf die speziellen Umweltanforderungen 

in den Aluminiumhütten 

angepasst wurde. Die eingesetzten 

Schienenhalter mit Isolatoren erhö- 

each case two potrooms form one potline. 

Four to five cranes are in use on 

each crane track. These can change 

over from one track to another along a 

transverse transfer axis approximately 

at the middle of the crane tracks. To 

achieve uninterrupted energy supply 

even during the transfer process, special 

transfer sections with incoming 

and outgoing stretches are used. 

Owing to the large temperature 

differences involved, the unusually 

long length of the crane track makes 

it essential for the length expansion 

pieces of the individual conductor 

rails to be robust and reliable. The 

expansion pieces are required to compensate 

expansions occurring in the 

buildings. The suspension of the conductor 

rails is also subject to special 

requirements. The suspension system 

must on the one hand be very robust 

and stable, and on the other hand it 

must permit unimpeded expansion of 

the conductor rail sections. 

“For energy and data transmission 

to the PTMs we mainly use single-pole 

insulated aluminium conductor rails 

of type 813 that can carry a nominal 

current of 1,000 ampères”, explains 

Mr Seidel. Particularly the extremely 

long travel paths of the cranes in the 

potrooms and the high currents they 

need to make them move proved decisive 

for the correct choice. The combination 

of aluminium and stainless 

steel provides a cost-optimised solution 

for this special application. By 

means of detailed and project-specific 

engineering the systems have been 

optimised in order to cover the high 

energy needs even when the PTMs 

are static. 

Thanks to the modular structure 

of the conductor rail product range, 

short crane tracks or changed current 

demands can be realised in a cost-efficient 

manner by means of smaller 

cross-sections (from 500 A) or by using 

the smaller 0812 series. The components 

are standardised and can 

even be fitted efficiently and inexpensively 

by less experienced installation 

companies in a short time. 

important: the correct insulation 

“The gases, vapours and dust usually 

generated during aluminium produc- 


Photos: Norsk Hydro 

Norsk Hydro setzt die Schleifleitungen von Conductix-Wampfler 

unter anderem in der Slovalco-Hütte ... 

Norsk Hydro uses Conductix-Wampfler conductor rails in its 

Slovalco smelter … 

tion and the high temperatures involved 

demand heat-resistant insulation 

of the conductor rails”, stresses 

Herman Thoma, project engineer in 

the process crane division at Conductix-Wampfler. 

In the anode production 

area the atmosphere is heavily 

laden with carbon and is very humid, 

which increases the risk of current 

spark-over. “Here we use special insulators, 

for safety reasons”, he says. 

The insulator material enables the 

conductor rail equipment to be operated 

at a higher working temperature 

optimally adapted to the special environmental 

conditions in aluminium 

smelting plants. The rail insulated 

holders used substantially increase 

the distance between current-carrying 

parts of the equipment and prevent 

dangerous sparking-over between the 

phases and the structure of the buildings. 

The current collectors used satisfy 

the strictest requirements for robustness 

and stability. In the potlines 

only stable, double current-collector 

units with precisely guided steel arms 

are used. The only part 

subjected to wear is 

the carbon collector 

brush which, however, 

can be replaced easily 

during routine maintenance. 

In aluminium production 

in general 

safety and reliability 

play a major role. The 

huge smelters are usually 

located in remote 

areas and are operated 

round the clock whenever 

possible. Produc- 


ers in this intensely 

competitive market 

cannot allow any 

safety and/or quality 

compromise 

and the associated 

production stoppages. 

“First-rate 

consultancy is extremely 

important 

for our customers”, 

stresses Mr Seidel. 

“Since Conductix- 

Wampfler can offer 

a very broad product 

range for energy 

and data transmission, the advice we 

give is fundamentally neutral and not 

focused on particular solutions because 

no alternatives are available. 

This enables us to make professional 

recommendations best suited to the 

needs of the customer for producing 

the perfect technical design for energy 

supply as regards both safety and 

cost efficiency.” Other advantages are 

quick reaction times, accuracy of detail 

and open, clear communications. 

The focus in the electrification of 

crane units in aluminium smelters is 

on the supply of energy to the potlines 

by conductor rails. Special requirements, 

however, also apply to rotating 

or tumbling applications which, 

from the project planning stage, have 

to be optimally designed and matched 

to the plant concerned. The large 

product range of Conductix-Wampfler 

enables aluminium smelters to 

be equipped in the best way possible 

with all types of products for mobile 

energy and data transmission. 

… und in Sunndal ein … and in its Sunndal smelter 

■ 


hen den Abstand zwischen stromführenden 

Teilen der Anlage entscheidend 

und verhindern gefährliche 

Spannungsüberschläge zwischen den 

Phasen und der Gebäudekonstruktion. 

Auch die eingesetzten Stromabnehmereinheiten 

erfüllen höchste 

Anforderungen an die Robustheit 

und Beständigkeit. In den Elektrolyselinien 

kommen ausschließlich stabile 

Doppelstromabnehmereinheiten 

mit präzise geführten Stahlarmen 

zum Einsatz. Einziges Verschleißteil 

ist die Abnehmerkohle, die sich aber 

bei regelmäßiger Wartung leicht austauschen 

lässt. 

Sicherheit und Zuverlässigkeit 

spielen in der Aluminiumherstellung 

generell eine große Rolle. Die riesigen 

Anlagen liegen meist in abgelegenen 

Gebieten und werden möglichst rund 

um die Uhr betrieben. Sicherheitsund/oder 

Qualitätsmängel und damit 

verbundene Produktionsausfälle 

können sich die Anbieter in diesem 

wettbewerbsintensiven Markt nicht 

leisten. „Unsere Kunden legen daher 

großen Wert auf eine exzellente Beratung“, 

betont Seidel. „Da Conductix- 

Wampfler ein sehr breites Produktportfolio 

in der Energie- und Datenübertragung 

anbieten kann, ist unsere 

Beratung grundsätzlich neutral und 

nicht auf bestimmte Lösungen fixiert, 

weil Alternativen nicht im Angebot 

sind.“ So könne man professionell 

und zum Nutzen des Kunden die perfekte 

technische Auslegung der Energiezuführung 

in Bezug auf Sicherheit 

und Kostenoptimierung empfehlen. 

Weitere Vorteile sind schnelle Reaktionszeiten, 

Detailgenauigkeit und eine 

offene, klare Kommunikation. 

Der Schwerpunkt bei der Elektrifizierung 

von Krananlagen in den Aluminiumhütten 

liegt in der Energieversorgung 

der Elektrolyselinien durch 

Schleifleitungsanlagen. Besondere 

Anforderungen werden aber auch an 

drehende oder trommelnde Applikationen 

gestellt, die im Zuge der Projektplanung 

und Ausführung optimal 

ausgelegt und auf die jeweilige Anlage 

abstimmt sein müssen. Die große Produktpalette 

von Conductix-Wampfler 

ermöglicht die bestmögliche Ausstattung 

der Aluminiumhütten mit jeglicher 

Art von Produkten für die mobile 

Energie- und Datenübertragung. ■ 

43


EMC confirms its quality lead 

increase in capacity at Amag casting in Ranshofen 

M. Bolliger, B. F. Prillhofer 

Fig. 1: Overview of the new EMC casting pit 

EMC (Electro Magnetic Casting) 

has established itself as the 

cutting-edge technology for the 

continuous casting of aluminium 

alloys. Recent development work 

has further confirmed its outstanding 

advantages for the 2xxx, 

3xxx, 5xxx and 7xxx alloy groups. 

EMC began in the late 1960s. At that 

time, a Russian team led by Z. N. Getzlelev 

(ref. Dobatkin [1]) developed 

the continuous casting of aluminium 

alloys in an electromagnetic mould. 

In 1973, the former Alusuisse purchased 

the Russian patent rights and 

brought the process up to large-scale 

rolling slab production. Alusuisse 

later bought the commercial rights to 

the process and thus the equipping 

of third-party firms. In 1988, Austria 

Metall AG (Amag) Ranshofen decided 

to buy the technology and put a casting 

line into service. The main use of 

the new line was to cast alloys susceptible 

to hot (3xxx and 5xxx) and cold 

cracking (2xxx and 7xxx) up to a rolling 

ingot size of 1,680 x 310 x 7,200 

mm (width x thickness x length). 

Over the years, Amag casting 

GmbH has built up comprehensive 

know-how with regard to wrought alloys 

susceptible to hot and cold cracking. 

In combination with the desire to 

expand its production capacity, this 

ability motivated Amag casting to 

install a second EMC casting line in 

2008. With this new casting line, the 

company can now produce rolling 

slabs in sizes of up to 2,320 x 600 x 

7,200 mm (see Fig. 1). 

eMc technology in brief 

EMC can be generally classified as 

belonging to the group of semi-continuous, 

vertical continuous casting 

processes in which metal feeding 

takes place via a melt distribution 

system consisting of a nozzle, a plug 

valve and a glass cloth filter sack. 

The contours of the solidifying metal 

are determined in a water-cooled 

mould. These processes are known 

as DC (Direct Chill) casting because 

of the cooling by water jets, which 

quench the freshly solidified aluminium 

surface just below the mould. 

In the conventional DC process, the 

liquid metal solidifies superficially in 

direct contact with the mould wall. 

This requires a mould lubricant (e. g. 

greases containing graphite, etc.) in 

order to reduce friction and adhesion 

of aluminium on the mould. The thin, 

solid crust then loses contact with 

the mould before reaching the direct 

cooling zone. This interrupted cooling 

causes reheating in the ingot surface. 

The solidification rate fluctuates and 

produces an irregular cast structure 

in a shell zone, which is about 10 to 

20 mm thick (Fig. 2). This zone has 

a coarser cell size as well as regions 

with inverse segregation, i. e. higher 

Fig. 2: Schematic diagram of the principles Fig. 3: Schematic diagram of the principles 


Fotos & Grafiken: Amag casting

concentrations of alloying elements 

on the surface and lower below the 

surface. The thickness of this shell 

increases linearly with contact time, 

that is with the length of the mould 

wall in the casting direction. This zone 

must be machined off before rolling, 

involving an expensive milling (scalping) 

operation, a large volume of machining 

chips (swarf) to re-melt and a 

considerable loss in casting yield [2]. 

The EMC mould (Fig. 3) is ideal for 

DC casting. As opposed to a conventional 

mould, in the EMC mould the 

liquid metal column never touches 

the mould surface, because it is supported 

by an electromagnetic force. 

This force derives from a magnetic 

field produced by a high frequency, 

alternating current in the mould. It 

holds the liquid metal away from the 

mould surface, so that a distinct shell 

zone does not form on the ingot surface. 

Therefore, EMC rolling ingots 

have a very smooth surface and a 

uniform cast structure with the result 

that as a rule it is unnecessary to machine 

off the ingot surface. Furthermore, 

the hot-rolled strip is almost 

free of edge cracks and does not need 

edge trimming [3-5]. 

Advantages of the direct 

combination of eMc technology 

with the rolling process 

In order to exploit the advantages 

of EMC technology to the full, the 

process chain, including the rolling 

process, must be considered in its 

entirety. For the economics of EMC 

technology purely from the perspective 

of casting, it is easy to dismiss 

EMC as uneconomic by using arguments 

such as: 

• High investment costs 

• Extremely complex plant 

automation 

• High operating costs due to the 

electrical energy requirement 

• The need for comprehensive 

operator know-how. 

However, if one extends this limited 

field of vision to include the 

further processing phases included 

in subsequent rolling, these alleged 

problems can be clearly counterbalanced. 

In the final analysis, the 

economic advantages generated 


by EMC technology are as follows: 

• Reduction or elimination of edge 

cracking during hot rolling: During 

hot rolling, conventionally cast, hard 

alloy rolling ingots are subject to highly 

prevalent edge cracking. This leads 

to an increased volume of edging 

scrap and a considerable reduction 

in the working width of the hot strip. 

Edge cracks derive from the presence 

of a distinctive casting shell on the 

edges of the rolling ingots. This reduces 

surface strength and thus leads 

to the formation of cracks caused by 

the forces exerted during hot rolling. 

The only help in this situation is the 

use of an edge-milling device, but as 

a result of limited throughput and increased 

demands, this is uneconomic. 

By contrast, owing to their smooth 

cast surfaces, rolling ingots derived 

from EMC technology do not require 

any upstream edge milling. 

• No necessity for milling prior to 

rolling: EMC ingot surfaces have no 

inverse segregation, because as there 

is no primary cooling involving contact 

with the mould unstable thermal 

deflection with intermittent re-heating 

and partial re-melting does not 

occur. Due to these extremely stable 

process conditions, EMC ingots 

have a very smooth surface, and their 

microstructure shows a cell size that 

increases continuously from surface 

to core (Fig. 3) [5]. Therefore, it is unnecessary 

to machine the wide faces. 

The advantages above save up 

to 10% in gross input weight of the 

rolling ingot. They also eliminate the 

intermediate ingot machining operation 

with its trimming scrap for recycling, 

and thus reduce operating costs. 

Hence, the higher investment and operating 

costs for EMC technology in 

the cast house are thoroughly justified 

in an overall assessment of the cast 

house and rolling mill. Together with 

Amag rolling GmbH, Amag casting 

GmbH can therefore offer customers 

an innovative product, which is costefficient 

and ecologically optimised. 

the physical background 

to electromagnetic casting 

The electromagnetic casting process 

requires two main prerequisites. The 

first is a very powerful electric current 


(in this case about 6,600 A) and the 

second, a screen in the mould (again 

Fig. 3), which shapes the magnetic 

field in order to control the solidifying 

liquid metal. This screen also guides 

the cooling water and ensures the 

correct angle of impact on the ingot 

surface. 

The flowing electric current I in 

the inductor strip generates a magnetic 

field H, the intensity of which 

decreases with distance r from the 

conductor (Fig. 4). 

Fig. 4: Form of the magnetic field 

The intensity of the resulting magnetic 

field H is given by the following 

equation (I is the current in amperes 

and H is the magnetic field in amperes 

per metre (A/m) at a radius r): 

I 

H = ⎯⎯ [Am -1 ] 

2πr (1) 

It is known that an alternating magnetic 

field induces an electric current 

in a conductor within this field (principle 

of alternating current generators 

and voltage transformers). In this 

specific case, the current alternates 

at a frequency of 2,500 Hz (cycles 

per second). The generated electromagnetic 

force F that works against 

the conductor, in this case the liquid 

metal, is given by the Lorenz’s Law, 

which can be expressed as following 

(l represents the vector of the current 

and B the magnetic induction in voltseconds 

per square metre): 

→ → → 

F = Il x B [N] (2) 

This equation exactly describes the 

force that can keep the liquid metal 

in equilibrium without it contacting 

the mould. As already mentioned, 

the second major component in EMC 

technology is the mould screen, ➝ 

45


which fulfils two functions. Firstly, it 

facilitates the formation of a uniform 

film of cooling water along the circumference 

of the ingot. Secondly, it 

weakens the magnetic field towards 

the top of the mould. This weakening 

is necessary for the correction of 

metallostatic pressure (proportional 

to liquid metal depth) and the surface 

tension of the meniscus. Therefore, 

the magnetic field strength must exactly 

follow a given curve in order that 

the meniscus is as close to 90° as possible. 

If this weakening is insufficient, 

the electromagnetic force is too strong 

at the upper levels and will push the 

meniscus further away from the 

mould. This would halt the supply of 

liquid metal to the ingot surface plane 

and corners and thus prevent stable 

casting conditions, causing defects 

such as cold shuts (cracks in which 

liquid metal does not weld to an already 

solidified meniscus), or even 

liquid metal breakouts. 

A further benefit of EMC casting 

is the turbulence caused by magnetic 

induction in the liquid metal sump 

(counter-current vortices). This turbulence 

stirs the liquid metal and 

partially explains the uniform distribution 

of alloying elements and the 

lack of macro-segregation in the edge 

zone. Furthermore, it produces a finer 

grain structure by breaking off dendrite 

arms and thus generating new 

grains. 

Preconditions for eMc casting 

The most important preconditions for 

achieving optimum productivity with 

the EMC process are: 

Technical requirements 

• Suitable electrical equipment (frequency 

generator, transformer, parallel 

capacitors, etc.) to produce a 6,600 

A current alternating at a frequency of 

2,500 Hz. 

• A robust casting unit with precisely 

built components such as a casting 

table, mould frames, starting heads 

for moulds and the related support 

plates, metal distribution channels, 

etc. In particular, the mutual centring 

of the distribution channels is vital to 

the casting process, as otherwise good 

reproducibility cannot be guaranteed. 

• Due to the explosion risk created 

Fig. 5: Sequence of GAPCast process automation phases 

by the proximity of liquid aluminium 

and water, the exact control of the 

casting parameters is essential. This 

is only possible using real-time processes 

control systems. 

Process-related requirements 

• The inductor produces a magnetic 

field, which occupies a precisely 

defined area. Therefore, the liquid 

metal in the mould must be kept at 

a constant level (tolerance of only a 

few millimetres). An excessively low 

metal level would lead to liquid metal 

escape (bleed-outs), while unduly 

high metal levels can result in contact 

between the liquid metal and the 

screen. Furthermore, fluctuations in 

metal level can result in a wavy ingot 

surface and thus scrap rejects, or the 

need to mill the ingot surface. 

Supporting technologies 

for a successful start-up 

of the casting process 

Ingot foot deformation (butt curl) is a 

well-know defect at the start of casting, 

especially in the case of large rolling 

ingots. Special start-up methods 

can largely eliminate this problem. 

These methods allow a reduced cooling 

intensity during start-up (non-stationary 

casting phase) to reduce the 

thermal stresses that cause ingot foot 

deformation. At present, two industrial-scale 

technologies provide this 

flexible cooling intensity. 

CO 2 technology: This technology 

injects liquid CO 2 into the cooling 

water circuit at a distance that is sufficiently 

far upstream to ensure that 

by the time it reaches the mould, it 

is totally dissolved and uniformly distributed. 

As soon as the water leaves 

the mould nozzle and quenches the 

hot ingot, CO 2 emerges as small bubbles. 

These bubbles stick to the ingot 

surface and form a stable insulating 

layer of water vapour and CO 2 , which 

practically prevents thermal transfer 

as long as the injection of CO 2 continues. 

Pulsed water technology: Briefly 

interrupting the cooling water supply 

represents another method of reducing 

cooling during the start-up phase. 

As mould cooling cannot function at 

low pressure or flow rate, because the 

water would then simply fall straight 

down without touching the ingot, the 

cooling water jet is interrupted periodically 

for a few tenths of a second 

between two pulses. Hence, this technique 

is called pulsed water cooling. 

Process automation 

As mentioned at the beginning of 

the paper, full automation is an essential 

precondition for the reliable 

operation of EMC technology. Using 

process automation from ‘GAPCast’ 

[6] provides the following important 

advantages: 

• Central data collection of all 

casting parameters 

• Detailed logging of the entire 

casting operation 

• Reproducible ingot quality 

• Simpler technology transfer 

(documentation of casting recipes 

for all alloys and formats) 

• Improved safety in the workplace. 

The main role of the process control 

unit is to calculate, check and adjust 

all important parameters before and 

during the cast on the basis of the 

stored casting recipe. This is achieved 


Fig. 6: Overall layout of the casting unit 

by continuously feeding reference 

target values into an autonomous 

control system. Process control is divided 

into different phases, as shown 

in Fig. 5. The various process phases 

can be characterised as follows: 

Check phase: During the check 

phase and already in the automation 

mode, the processor calls up the casting 

recipe and checks it for plausibility. 

The casting operator, who is familiar 

with the automation program, 

works through the checklist to confirm 

that all important plant components, 

control elements and sensors 

are ready for the casting operation. 

Then the program releases the plant 

for the subsequent start phase. 

Start phase: During the start phase, 

the key process parameters are progressively 

activated according to the 

recipe until they reach the levels of the 

so-called ‘stationary’ phase, when the 

casting parameters are in a steady state. 

Casting phase: Prior to the start 

phase and until, as well as during 

the whole casting phase, the process 

automation system has the task of 

observing the entire casting unit, as 

well as checking the variable casting 

parameters against their target values. 

The system records any unexpected 

events, sends alarm messages if the 

parameters differ from the normal 

range and activates a rapid or an 

emergency stop procedure if deviations 

overshoot the permitted limits. 

End Phase: The end phase starts automatically, 

a few centimetres before 

the cast length reaches its target value. 

This serves to minimise the amount of 

liquid metal lost in the launder and to 

respect the target length. 

Plant layout 

The new EMC II casting unit for Amag 

casting GmbH was designed and built 


by Rihs Engineering, in collaboration 

with GAP Engineering (casting 

automation) and Elotherm (medium 

frequency power input). 

The plant layout is designed for the 

production of six rolling ingots with 

maximum dimensions of 1,680 x 380 

x 7,200 mm. These can be either cast 

using EMC or Wagstaff’s LHC (Low 

Head Casting) process [7]. It is equally 

possible to cast four EMC 2,300 x 600 

x 7,200 mm ingots. The EMC 1,680 x 

380 mm size uses adjustable moulds 

with widths that can be varied between 

1,050 and 1,680 mm. Furthermore, 

as explained above, the cooling 

water system can be equipped with 

the CO 2 or the pulsed water process. 

Fig. 6 depicts the overall layout 

of the casting unit. The figure on the 

right shows the casting position and 

the one on the left the service position. 

The service position is used for 

all ancillary operations, including 

maintenance, the removal of the cast 

rolling ingots, preparing the launder 

for the next cast, and changing formats 

(moulds). 

Summary 

With the increased capacity provided 

by the second EMC technology, casting 

unit, Amag casting has succeeded 

in extending its excellent continuous 

casting quality to a wider range of 

products. This will enable Amag casting 

to even more clearly underline its 

image as a premium quality producer. 

Based on the experience and comprehensive 

user know-how of Amag casting, 

casting recipes for new alloys can 

be established very quickly. A global 

view of the whole process chain from 

the raw material to the end product 

proves the advantages of EMC with 

regard to numerous products that 

were previously cast using conven- 


tional DC, as the switch to EMC increases 

yields and saves ingot milling 

and other operations. For products, 

with regard to traditionally EMC cast 

products, the new plant extends the 

ingot thickness range to 600 mm. 

With EMC technology, Amag casting 

can produce a broader spectrum 

of continuous cast products of the 

highest quality. As a consequence, the 

company can pass this advantage on 

to its customers in the form of innovative 

rolled products. 

Acknowledgements 

The authors wish to thank Austria 

Metall AG (Amag) for the close collaboration 

and permission to publish 

this article. 

References 

[1] V. I. Dobatkin et al., Continuous casting 

in an electromagnetic mould (in Russian), 

Moscow, Metallurgia 1983 

[2] Schneider, W.: Stranggießen von 

Aluminium-Werkstoffen. Stranggießen. 

Oberursel: DGM Informationsgesellschaft, 

1995, p. 3-20. 

[3] Bermudez, A.; Muniz, M. C.; Salgado, P.: 

Asymptotic approximation and numerical 

simulation of electromagnetic casting. 

Metallurgical and Materials Transactions 

B (2003), 34B, p. 83. 

[4] Kim, S. W.; Hao, H.: Microstructure and 

fatigue characteristics of direct chill cast 

and electromagnetic cast 2024 Al alloy 

ingots. Metallurgical and Materials Transactions 

A (2003), 34A, p. 1537-1543. 

[5] Suppan, H: Operational experiences 

with electromagnetically cast hard-alloy 

aluminium sheet ingots. Erzmetall 44 

(1991), No. 6, p. 306-309. 

[6] GAP Engineering SA: Description of 

GAPCast automation, 2010 

[7] Wagstaff, R. B.; Bowles, K. D.: Practical 

Low Head Casting (LHC) mould for aluminium 

ingot casting. Light Metals (1995), 

p. 1071-1075. 

Authors 

Martin Bolliger, a casting technology consultant, 

was formerly deputy vice-president 

of Alusuisse / Alcan Technology & 

Management Ltd in Switzerland. He has 

designed and installed EMC casting machines 

at many different sites and is an 

independent expert in this area. 

Dr. Bernd F. Prillhofer is an assistant to 

the technical management and head of 

the plant described above at Amag casting 

GmbH in Ranshofen in Austria. 

Amag Austria Metall is an exhibitor 

at ALUMINIUM 2010. Hall 7, 

Stand E30. 

47


Production planning in the aluminium recycling 

industry made easy with an add-on to SAP eRP 

H. Friedrich, K. Dieing, Th. Sedlak, J. Schröder 

The main tasks in the aluminium 

recycling process go beyond the 

production of aluminium alloys 

from the available scrap and its 

qualitative attributes. There are 

numerous customer orders that 

demand different alloy mixtures 

to be delivered on different dates 

with different qualities and quantities. 

The amount of detailed data 

regarding the calculations and 

planning of this process requires a 

large amount of technical support. 

This paper describes a problem 

in the production preparation and 

scheduling in the secondary metal 

production and presents its solution 

using the SAP ERP and OR 

Soft’s Manufacturing Workbench 

Burden Optimisation. 

In the past, meeting customer requirements 

with existing market solutions 

meant using stand-alone systems and 

software that required a specific hardware 

and software environment. Today, 

companies using standard ERP 

systems such as SAP ERP have the 

opportunity to use OR Soft’s Manufacturing 

Workbench Burden Optimisation, 

a software solution that 

combines batch management, burden 

optimisation and production planning 

all within a single product. The 

following text will describe this standard 

software solution. The software 

is a functional extension of the SAP 

ERP modules PP (production planning) 

and PP-PI (production planning 

for the production industry), which 

satisfies customer demand through 

the use of easily handled software in 

a professional system landscape. 

1. introduction 

This article reflects on the initial 

problems and solutions to production 

planning in the metal production 

industry, e. g. the extraction of aluminium 

from various types of metal scrap 

and aluminous recycled materials. The 

situations presented are actual situations 

that a planner could come across 

during a day at work. First, the initial 

situation is described, followed by the 

definition of the problem. Then a general 

approach to solve these problems 

is presented, and, finally, concluded 

with a discussion on how OR Soft’s 

Manufacturing Workbench Burden 

Optimisation can be used as a solution 

for production planning problems in 

the metal production industry. 

2. initial situation 

The supply of the raw materials is 

predominately assured through the 

accusation of scrap. This section describes 

the production process and 

constraints associated with aluminium 

recycled materials. 

1. Scrap batches are delivered. 

2. Visual inspection of quality, characteristics 

and conditions. 

3. Material group and a storage bins 

are assigned to the batch for unique 

identification. 

4. Analysis measures the humidity, 

volatile elements, free iron, fine parts 

and other impurities. The melting 

yield and chemical composition is 

analysed through melting. 

5. The batch is reduced to smaller 

pieces through shredding or cutting, 

and major impurities are stripped 

away. 

6. The available raw material batches 

of various qualitative attributes are 

blended with consideration to the 

quality demanded by the customer. 

7. Note that the pieces of the alloy 

elements (chemical analysis) are constrained 

by an upper and lower bound 

and that the permitted mixtures are 

constrained by a maximum value. The 

procedure for the combination of the 

batches is known as burden optimisation. 

8. The burden optimisation is specially 

used for the optimisation of 

raw materials in order to minimise the 

production costs. The number of the 

different raw material batches, specified 

up to their 30 th characteristic, 

allows the producer to calculate the 

required combination of the metals. 

9. Emission constraints for the melting 

process must be considered as 

well. 

The requirements for a production 

plan have now been completed. 

If you face a production period of five 

days, with three shifts per day, and 

100 running production cycles per 

week (batches), you should consider 

a production planning system. Such a 

system should also create and handle 

a machine allocation plan (furnace, 

converter and pig-casting conveyors). 

3. Problem definition 

The optimisation of the production 

process should decrease production 

costs. The solution to the problem 

consists of a two step process. The 

first step handles the planning of the 

production capacities (resource allocation). 

The second step includes the 

identification of an allowed BOM in 

the process orders (burden optimisation). 

The SAP ERP module PP-PI 

contains all the necessary functionalities 

required to display the production 

cycle. The SAP ERP supports 

decision making and the creation of 

machine allocation processes, but 

not to a satisfactory level. Moreover, 

functional support does not exist for 

the computation of an optimisation 

problem. 

3.1. Scheduling 

A number of aggregates are necessary 

for the production of aluminium alloys. 

The planning process takes into 

account, among others, the following 

machine capacities: 

• Processing machines (ball mill, 

swarf drying, etc.) 

• Charging machines, etc. 

• Melting furnaces (rotatory furnace, 

hydraulic tippable aluminium cast- 


Grafiken: OR Soft Jänicke 

ing furnaces, etc.) 

• Metal collector (converter, 

furnace, etc.) 

• Pig-casting conveyors 

• Cooling equipment 

• Packaging (stacking equipment, 

circular saws, etc.) 

Production planning systems support 

the smooth flow of production and 

immediately alert to bottlenecks or 

other critical situations. Additionally, 

they help to quickly identify and execute 

alternatives plans during downtimes 

or breakdowns. The goal is to 

detect and prevent any waiting hours 

or idle time during the production 

process. 

3.2. Burden optimisation 

The burden optimisation handles the 

determination of entry batches and 

quantities so that the desired customer 

product requirements, including 

the value of the stock, are met while 

taking into account the melting and 

environmental concerns. At the same 

time, burden optimisation administers 

the inventory and provides an 

overview of the quantities should be 

given. The values of the stock are part 

of these requirements. 

4. general solution approach 

The solution for the task describes follows 

the subsequent steps: 

• Selection of the customer orders 

for weekly production (calendar 

week) 

Fig. 1: Allocation planning 


• Assignment of customer orders 

to production orders (quantity 

and date) 

• Scheduling of the production 

orders (capacity planning) 

• Assignment of the raw materials 

to production orders (burden 

optimisation). 

For these and many other reasons, 

a stable solution is preferred: one 

which allows the planner to simulate 

and evaluate different potential plans. 

Such a solution must be easy to use 

and have an intuitive visualisation of 

the results as well. The seamless integration 

of this solution in a system 

environment is also essential. 

The Manufacturing Workbench 

is an SAP endorsed business solution 

(EBS) which greatly enhances 

the functionality of an SAP system. 

This solution’s ‘Burden Optimisation’ 

module has been an exceptionally attractive 

and effective solution for the 

SAP ERP systems within the metal 

producing industry, strengthening 

their rough-cut planning and detailed 

scheduling processes. 

5. Detailed solution with 

Manufacturing Workbench 

Manufacturing Workbench is an APS 

tool, which acts like an add-on to the 

SAP modules PP and PP-PI. This tool 

loads all the master and dynamic data 

from the SAP ERP and writes back the 

planning results to the system without 

creating an additional local database. 

Purchase, sales and quality inspection 


processes can also be carried out with 

the help of the Manufacturing Workbench. 

From the author’s experience, there 

exist two major workplaces within a 

typically production facility: one for 

scheduling and another one for the 

burden optimisation. Both workplaces 

use the same interface and load all 

the necessary data during start-up. 

However, if it happens that a single 

planner must perform both tasks, the 

Manufacturing Workbench can include 

all of the functionalities needed 

in one workplace. The Manufacturing 

Workbench can have two different 

workframes allowing the planner to 

easily switch between them. 

5.1. Detailed scheduling 

The planning tool gives provides the 

planner with the option to overview 

the current production situation in 

tabular and graphical form. Additionally 

it offers the following options: 

• Simulation of production 

• Drag and drop function for 

scheduling and rescheduling 

• Manipulation of production 

orders 

• Drill down to detailed information 

(components, customer relations, 

possible delivery delay, availability 

of raw materials, etc.) 

• Immediately see the outcome of 

decisions regarding material and 

capacity 

• Insert flexible short-term contracts 

• Use different strategies to calculate 

production plans 

• Optimise sequences 

• Use assets to maximum 

capacity, without 

any wait time. 

The first task of the production 

planner is to 

generate a process order 

from the customer 

order, then allocate and 

schedule it. Scheduling 

must take into account 

the setup cost of the 

cleaning processes, the 

capacities of the furnaces 

and the delivery 

date of the customer 

order. 

The allocation ➝ 

49


planning is executed with the help 

of a graphical user interface (see Fig. 

1). Through the use of a Gantt-chart, 

one can do almost all of the planning 

operations through drag and drop. For 

precaution and better handling, this 

is first done in simulation mode, 

meaning that changes are saved only 

in the local user PC. After the simulation 

is confirmed, the changes are 

saved and actualized in the SAP ERP 

system. 

5.2. Burden optimisation 

An additional component solution is 

configured for the realisation of the 

mixture bill, allowing the selection 

of the amount and type of necessary 

batches in a production order. 

Once the production planner has 

generated a production order from 

a customer order, a standard work 

plan is selected. At this point, there 

is no BOM in the production order, 

but it is shown once the batches and 

quantities of the burden optimisation 

are assigned to the production order. 

This results in the expected alloy parameter 

of the product and the gross 

and net quantities of the orders. Note 

that changes can be made to the work 

plan to modify the melting duration 

process. 

Fig. 2 shows an example of the 

user interface in the burden optimisation: 

there is a list of material 

inputs for the production order, the 

quality parameters are calculated, 

and if one more batch 

is added/removed or 

if the input quantities 

are changed, the gross 

and net amounts are 

actualised with regards 

to the burden optimisation. 

You can only use 

batches and quantities 

which have not been 

already assigned. 

The value of the 

material input can be 

calculated immediately. 

User must consider 

the material input value 

and turnover rate from 

to the customer order 

to calculate the profit 

margin. 

There are several possible ways for 

the planner to compute a BOM. One 

of these way is to select the batches 

manually, and/or using a linear optimiser. 

When using an LP solver the 

results can be manipulated in two 

different ways. First, the mathematical 

model can be extended or manipulated 

before running the optimiser. 

There is a pool of constraints within 

the model which the user can use to 

activate/deactivate any specific constraint 

to prevent the use of certain 

batches. Note that the model parameter 

(quality parameter range or allowed 

production range) can also be 

changed or manipulated. The other 

option is to do the post-editing of the 

results manually, giving you the opportunity 

to edit the quantity, add/remove 

specific batches. 

One of the biggest challenges of a 

manual manipulation is considering 

all 30 quality parameters. The Manufacturing 

Workbench supports the 

user by showing all quality violations. 

If the optimiser is used, the user benefits 

from knowing that all the results 

are already within the allowed range, 

and that no violation exists. The results 

can be compared in a graphic 

and/or table mode (see the right side 

of the Fig. 2). 

6. conclusion 

Fig. 2: Burden optimisation 

The Burden Optimisation is the only 

combined optimisation tool in the 

market with plant occupancy plan- 

ning for the SAP ERP. The SAP ERP 

can be easily upgraded by a local expansion 

to add the needed functionalities 

through the approach discussed 

within this article. There is no need 

to make any changes in the SAP ERP 

configuration. 

Furthermore, there is a link between 

the simultaneous material 

and capacity planning in the burden 

optimisation. This allows the entire 

planning process to be addressed in 

a single interface, thus avoiding any 

restrictions caused by the separation 

of material planning, accounting 

mix, and capacity planning in the 

modules PP and PP-PI. Through the 

use of these plans and a better demand 

forecast, the sales personnel 

can provide their customers a more 

precise delivery statement regarding 

the orders. 

The Manufacturing Workbench 

Burden Optimisation provides the 

opportunity to extend the powerful 

functionalities of SAP ERP Product 

Planning modules under one aggregated 

system, making it an invaluable 

tool that is perfectly fitting to the 

metal producing industries. 

Authors 

Hartmut Friedrich and Jens Schröder are 

with OR Soft Jänicke GmbH 

Thomas Sedlak and Karl Dieing are with 

Oetinger Aluminium GmbH 


aluminium smelting industry 

Hydro shareholders approve 

Usd1.6bn rights issue 

Norsk Hydro shareholders have approved 

a NOK10.02bn (USD1.6bn) 

rights issue that will partly finance 

the purchase of Vale’s aluminium 

business and support the company’s 

investment grade rating. Hydro’s 

share capital will be increased by 

around NOK418.4m through an issue 

of 381,053,600 new shares. 

The subscription price will be 

NOK26.30 per share, representing a 

discount to the theoretical ex-rights 

price of about 26% based on Hydro’s 

closing share price of NOK38.50 

on June 18. Existing shareholders 

will receive seven transferable subscription 

rights for every 23 existing 

shares held. The Norwegian state, 

which owns 43.3% of Hydro, backs 

and has agreed to participate in the 

rights issue. Folketrygdfondet, the 

government pension fund of Norway, 

has also undertaken to subscribe and 

underwrite 5.8% of the rights issue. 

Flooding prompts alcoa idling 

spanish aluminium smelter 

Alcoa Inc. has declared force majeure 

on deliveries from its aluminium 

smelter in Aviles, Spain, due to 

severe flooding in the region. The 

smelter, which has a nameplate ca- 


pacity of 93,000 tpy, but has been 

operating at a slightly reduced rate 

of some 90,000 tpy, has been temporarily 

idled as a result of torrential 

flooding in the northern province of 

Asturias. Floodwater entered both the 

smelter and the electrical substation 

that supplies power, forcing the decision 

to idle. Now an assessment of 

damages and a full cleanup must take 

place, before the plant can be brought 

back online. 

News of the temporary shutdown 

comes as Alcoa continues to await a 

European Commission decision as 

to whether energy tariffs provided 

to the company’s Spanish smelters 

by the Spanish government should 

be considered illegal aid. The investigation, 

which focuses on activity in 

2005, was opened on the assumption 

that Alcoa’s electricity charges in the 

country were artificially low. Alcoa 

could look to close its three Spanish 

operations if the commission does not 

rule in its favour in a decision expected 

to be released later this year. 

rusal restructures 

its aluminium division 

UC Rusal will restructure its aluminium 

division in two units – East and 

West. The main task of the division 

East – which will include the company’s 

major aluminium production 

c o m p a n y n e w s w o r l d w i d e 

Norsk Hydro 

facilities, such as the Sayanogorsk, 

Khakass, Krasnoyarsk, Irkutsk, Novokuznetsk 

and Bratsk – is to meet the 

growing demand for Rusal’s products 

from Asia, increase the production of 

alloys and value added products. 

The division West – encompassing 

the Volgograd, Volkhov, Kandalaksha 

and Nadavoitsy smelters, Zaporozhye 

aluminium complex (Ukraine) 

and Kubal (Sweden), as well as the 

aluminium production facilities of 

the Urals and Bogoslovsk smelters 

– will concentrate its efforts on the 

production of value added products. 

The western smelters, situated near 

European customers, will focus on 

supplying end consumers. 

These changes are aimed at increasing 

the efficiency of management 

and production processes by 

specialisation. The division West 

will be headed by Aleksey Arnautov, 

while Vladimir Polin, formerly the 

senior vice president of Mechel, will 

lead the division East. 

emal signs financing agreements 

with export credit agencies 

Emirates Aluminium (Emal) has 

signed financing agreements with 

three export credit agencies to support 

the financing of its Taweelah-based 

smelter project. In doing so it has secured 

loan financing agreements for 

around USD737m (2.7bn dirhams) for 

a term of up to 15 years. Export-Import 

Bank of the United States (US Ex-Im), 

Euler Hermes Kreditversicherungs- 

AG (Hermes) and the Compagnie 

Française d’Assurance pour le Commerce 

Extérieur (Coface) will provide 

financing support for the smelter. ■ 

Bauxite and 

alumina activities 

australian government 

modifies tax reform 

The mining giants BHP Billiton, Rio 

Tinto and Xstrata breathe a sigh of 

relief after the Australian government 

decided early in June to replace the 

Resource Super Profits Tax with ➝ 

51


a Mineral Resource Rent Tax. The 

new resource tax will apply from 1 

July 2012 only to mined iron ore and 

coal. All other minerals, such as bauxite, 

are excluded. The rate of tax will 

be 30% applied to the taxable profit 

at the resource. 

The mining industry has demanded 

that any new tax should not be applied 

retrospectively, so that existing 

projects where investment decisions 

have already been made are not adversely 

affected. Another key issue 

has been that a competitive effective 

tax rate does not disadvantage Australia 

as an investment destination. The 

companies agree that the proposal 

presented by the government represents 

significant progress towards a 

minerals taxation regime that satisfies 

the industry’s core principles. 

“There is still a great deal of work 

to be done before this tax is enacted, 

and we will work constructively with 

the Government to ensure that the 

detailed design of minerals taxation 

maintains the international competi- 

tiveness of the Australian resources 

industry into the future and is in the 

long term interests of the industry 

and all Australians”, BHP CEO Marius 

Kloppers said. 

rio Tinto to increase 

production in australia 

Rio Tinto plans to increase the bauxite 

and alumina production at its Weipa 

and Gove operations in Australia in 

response to better prices and demand. 

Market conditions permitting, 

Rio Tinto expects to produce over 

18m tonnes in 2010 from the Weipa 

bauxite mine. Bauxite output from 

the Weipa mine in north Queensland 

fell to 16.2m tpy in 2009 from 20m in 

2008 due to lower prices during the 

global financial crisis. Rio Tinto also 

wants to raise alumina output at its 

Gove refinery to 3m tpy, from 2.5m 

tonnes in 2009, to take advantage of 

higher prices. 

■ 

recycling and secondary smelting 

End-of-life recycling of used aluminium beverage cans back into new cans or other highly 

valuable aluminium products saves up to 95% energy compared to primary production 

and helps to lower greenhouse gas emissions 

aluminium beverage can recycling 

in eU 27 increases to 63% 

The overall recycling rate for aluminium 

beverage cans in the enlarged 

EU 27 including EFTA countries and 

Turkey further improved in 2008 and 

stands now at 63.1%. It has improved 

from 61.8% in 2007 and from 57.7% in 

2006. This increase over the past two 

years represents an impressive extra 

carbon footprint saving of more than 

310,000 tonnes of CO 2 equivalents, as 

new figures from the European Aluminium 

Association (EAA) show. 

The total number of aluminium 

beverage cans consumed in wider Europe 

rose from 32 billion in 2007 to 

nearly 34 billion units in 2008, resulting 

in an overall aluminium share of 

more than 70% on the total European 

beverage can market. In Europe consumers 

use on average 42 aluminium 

cans per capita. The consumption 

of aluminium cans grew in Western 

Europe while consumption remained 

stable in most Central & Eastern European 

countries. 

Sales of filled aluminium beverage 

cans for the wider European markets 

including exports to non-European 

countries grew by more than 5% to 

39 billion units with strong growth in 

Western Europe of nearly 10% whilst 

Central and Eastern Europe increased 

by 3%. 

Recycling rates vary significantly 

from country to country. Germany, 

for example, is the top performer with 

a recycling rate of 96%. Switzerland, 

Sweden and Finland as well have recycling 

rates beyond 90%. Generally 

spoken, there is a continued clear 

upward trend across Europe. While 

most countries with well established 

deposit or take-back systems maintained 

their high recycling levels, 

other countries have improved as 

well. Local authorities and waste 

management operators are increasingly 

aware of the high scrap value 

of well sorted aluminium. Even in today’s 

difficult economic environment 

there is increased investment in the 

latest available sorting and recycling 

technologies. 

The aluminium industry supported 

by their partners, the can-makers, 

promote the sharing of best practices 

and additional collection and sorting 

activities at local level as key drivers 

in the continued recycling growth of 

used aluminium packaging. 

aleris international 

emerges from chapter 11 

Aleris International Inc. has emerged 

from Chapter 11, having completed 

its financial and operational restructuring. 

Aleris is a privately 

held company, majority owned by a 

committed ownership group led by 

certain investment funds managed 


FotografiaBasica

y Oaktree Capital Management, affiliates 

of Apollo Management and 

Sankaty Advisors. In conjunction 

with its emergence from Chapter 11, 

the company closed on its rights offering 

in the amount of USD609m, 

which is comprised of USD45m in 

ten year unsecured Notes and up to 

USD564m in new equity. Addition- 

aluminium semis 

alba eyeing expansion in europe 

Aluminium company Alba sees excellent 

growth opportunities in the 

European markets. The company’s 

chief executive Laurent Schmitt recently 

said that Europe presented 

a fantastic growth opportunity for 

Alba as the company remained committed 

towards increasing the global 

presence of its product portfolio. At 

present, sales to Europe amount to 10 

to 15% of Alba’s output. It is the company’s 

ongoing commitment to attract 

new customers, expand ties with industry 

leaders and position Bahrain 

as an attractive economic destination 

for international investors, the Alba 

chief said. 

Garmco to diversify 

its aluminium source 

Bahrain’s Gulf Aluminium Rolling 

Mill Company (Garmco) rethinks 

using Aluminium Bahrain as its sole 

supplier of aluminium. This could 


ally, Aleris has a new, fully committed, 

USD500m asset-based revolving 

credit facility and over USD300m in 

liquidity. Aleris Deutschland Holding 

GmbH, a non-operating holding 

company with no employees or operating 

assets, and which conducts 

no commercial business, has also 

emerged from Chapter 11. 

■ 

mark the end of an exclusive partnership 

that has been existing for almost 

30 years. Garmco said that Alba 

would still supply its aluminium until 

2012 but then the company would 

aim at sourcing its primary metal also 

from other smelters across the GCC. 

The move to diversify its sources of 

supply comes as Garmco intends to 

build a rolling mill with a 200,000 tpy 

capacity next to Sohar Aluminium’s 

smelter in Oman. 

novelis supplies aluminium 

sheet for new Bmw 5 

Novelis has been selected as the main 

supplier of aluminium sheet for the 

n Rolling mills cold/hot 

n Roll grinding machines 

n Continuous casters 

n Levellers/straighteners 

n Drawing machines 


Alba 

new BMW 5 sedan, which went on 

sale this spring. This model features 

lightweight aluminium sheet in the 

doors, hood, front fenders and reinforcement 

parts. In addition, BMW has 

specified Novelis Fusion technology 

for the door structures, which is likely 

to be the biggest-selling automotive 

application to date for this patented 

multi-layer aluminium product. Novelis 

Fusion technology is also used on 

the BMW 5 Gran Turismo and the 7 

sedan series. 

The use of Novelis Fusion has enabled 

the carmaker to manufacture 

one-piece aluminium door structures, 

with integral window frames, to a design 

that, according to Novelis, is not 

achievable with conventional aluminium 

sheet. The result is a 25% reduction 

in the weight of the door, when 

compared with a similar steel design. 

It is the unique combination of core 

properties and surface characteristics 

provided by the multi-alloy composition 

of Novelis Fusion that makes this 

possible. 

novelis: bright prospect for 

rolled aluminium products 

We purchase and supply: 

n Slitting lines 

n Cut-to-length lines 

n Coilers 

n Coil carriages 

n Rollformers 

New increases in the use of aluminium 

in automobiles, consumer electronics, 

packaging and infrastructure are 

among the top drivers for growth in 

rolled aluminium products, and concerns 

about sustainability are behind 

much of the trend, Philip Martens, 

president and COO of Novelis, said 

on an aluminium conference in Oslo 

in June. Sustainability was becoming 

a driver for more and more policy and 

product decisions, which would open 

opportunities for the environmental 

benefits of aluminium. Recycling was 

the key to a successful future for the 

aluminium industry, he said. Novelis 

estimates global demand for alu- ➝ 

Please ask for our sales list! 

n Tube welding machines 

n Extrusion presses 

n Joining presses 

n Packing lines for strips 

COILTEC Maschinenvertriebs GmbH · Silberkaute 4 · 57258 Freudenberg 

Phone +49 (0) 2734/271190 · Fax +49 (0) 2734/271195 

www.coiltec.de · email: info@coiltec.de 

53


minium will rise about four percent 

annually over the next five years, with 

growth in Asia being perhaps double 

that rate. 

new rolled products 

for solar technology 

Aluminium strip and sheet from Hydro 

have been used for solar collector 

frames and collector dishes for some 

time. Now comes a substrate from Hydro 

– made from aluminium strip with 

a particularly low surface roughness 

– which represents the most cost-effective 

base material for thin-layer 

photovoltaic modules. Another new 

product is HyBridAl, designed for 

concentrated solar power (CSP) systems. 

Here, aluminium strip is laminated 

with a special, highly reflective 

on the move 

Marcos Ramos, head of Alcoa’s European 

operations, has been appointed 

new chairman of the European Aluminium 

Associatio (EAA). 

Maxim Sokov has been appointed 

UC Rusal’s director for Corporate Strategy 

and Development. He replaces 

Artem Volynets, who joins En+. In 

his new position, Maxim Sokov will 

focus on new opportunities for Rusal 

to develop and diversify its businesses, 

and strengthening the company’s 

competitive advantages to increase its 

market value. 

Aleris International appointed Mike 

Keown vice president, Finance for 

Aleris Rolled Products North America. 

Ted Lehman, the current Aleris Americas 

CFO becomes vice president, Aleris 

Americas Metals Procurement replacing 

Mike Keown. 

UC Rusal established a new International 

Sales Directorate headed by Steven 

Hodgson, formerly the CEO and 

president of Rio Tinto Alcan’s Bauxite 

and Alumina Division. Rusal also established 

a directorate for Russia and CIS 

Sales, headed by Sergey Belskiy. 

Scott Evans has left Mitsubishi 

International Corp. in New York, where 

he was a senior aluminium trader, to 

join Goldman Sachs. 

and weather-resistant foil to ensure 

that the system works much more 

efficiently and has a long service life 

outdoors. Besides this reflector foil, 

Hydro also offers tried-and-tested 

substructures made from extrusions, 

as well as all other aluminium components 

for complete CSP systems. 

The most important new development 

from Hydro for solar thermal 

energy is HySelect, the world’s first 

patented selective coating which is 

applied to aluminium strip using the 

coil-coating process. As a cost-effective 

variant to established PVD-CVDabsorber 

coatings, HySelect offers a 

selective absorber coating with high 

absorbance values of 90% and emission 

values of 12%. 

HyGloss, a material still in the testing 

stage, is seen as an alternative for 

large-dimension solar mirrors which, 

until now, mainly consist of heavy, 

breakable glass. HyGloss offers high 

strength and high gloss. This aluminium 

composite material has a highpurity 

aluminium mirror-finish coating 

of 99.99% pure aluminium which 

is applied to a high-strength core alloy. 

This combination of properties 

– the reflectivity of the outer cladding 

together with the high strength of the 

inner core – can be encapsulated in a 

high-strength, high-gloss aluminium 

mirror through further processing of 

the surface. 

alcoa to purchase Traco 

Alcoa will purchase window and door 

manufacturer Traco, which serves the 

commercial building and construction 

markets. The company will become 

part of Alcoa’s global building 

and construction systems (BCS) business. 

The terms of the deal were not 

disclosed, but the transaction is expected 

to close by the end of the third 

quarter, pending regulatory approval. 

Traco, founded in 1943 as the 

Three Rivers Aluminum Company, 

offers a full range of window and door 

manufacturing and services, including 

engineering, extrusion, finishing and 

electrostatic painting, glass insulation 

and tempering, and glass lamination. 

The company employs 650 people at 

its headquarters and manufacturing 

operation in Cranberry/Pennsylvania, 

north of Pittsburgh. Over its history, 

Traco has taken a role in major 

projects, including the Statue of Liberty 

restoration. Traco replaced the 

25 windows in the Statue of Liberty’s 

crown. 

Uc rusal and HKUsT launch 

five-year research project 

UC Rusal and The Hong Kong University 

of Science and Technology 

(HKUST), one of the leading universities 

in Asia, are launching a fiveyear 

joint project aimed at strengthening 

scientific and educational ties 

between Russia and Hong Kong. The 

project will foster joint scientific 

research, address environmental issues, 

and promote cooperation between 

young scientists from the two 

regions. The total sponsorship budget 

of the project provided by UC Rusal 

is USD1.5m. The joint project will be 

implemented during the academic 

years 2010/11 to 2014/15. 

The project will, among others, 

fund a three-year research programme 

to develop a large-scale, pre-insulated 

fibre reinforced aluminium envelope 

and roof system, using an aluminium 

composite as an energy-saving and 

environmentally friendly material. 

This is an ambitious attempt to find a 

large-scale use for innovative materials 

in the construction sector and to 

extend an application of aluminium. 

new paint system from novelis 

Novelis has developed a new paint 

system called SuperWindy which 

is more resistant to weather agents. 

It has been generated a pre-painted 

aluminium product which boasts a 

superior behaviour in the aggressive 

environments and against any form 

of corrosion. High performances are 

obtained against UV rays resistance 

that is the main cause of colour variation. 

SuperWindy is a development 

that combines the outstanding qualities 

of the Windy brand – high elasticity 

and very good behaviour to bend 

– with the implement of a further 

paint barrier which maintains the col- 


our aspect unchanged over the time. 

SuperWindy lends itself into a wide 

range of applications in the cladding 

façade and windows’ profile markets, 

but it has specific features which 

makes it particularly versatile and 

adaptable to different segments and 

architecture applications. 

rusal and FGc Ues sign agreement 

for new power line cables 

UC Rusal and the Federal Grid Company 

(FGC) of the Unified Energy 

System (UES), the operator of Russia’s 

national grid, signed an agreement 

to manufacture new types of 

cables for overhead power transmission 

lines. The agreement was signed 

as part of the investment and innovation 

programmes currently being 

implemented by the two companies. 

The cooperation is aimed at creating 

production capacity in Russia to manufacture 

modern types of cables for 

power transmission lines, which will 

improve their reliability and capacity. 

The parties intend to begin manufacturing 

high-temperature cables, 

cables with improved aerodynamic 

characteristics, and vibration resistant 

self-damping cables from aluminium 

and aluminium alloys, capable 

of withstanding the impacts of the 

elements, in particular wind and ice. 

The use of the new cables will help 

prevent power outages during unfavourable 

weather conditions. At 

present, these types of wire are widely 

used abroad in power transmission 

lines in regions with difficult weather 

conditions; however, they are not 

produced in Russia. According to the 

agreement, Rusal will participate in 

building a plant to make the new types 

of cables as well as accessories associated 

with them. It is expected that 

the new factory will begin operation 

in the second half of 2011. ■ 

suppliers 

VHe supplies rotary bath crusher 

VHE of Iceland has developed the 

Stimir robust rotary crusher. The unit 

is suitable for pre-crushing of large 


bath pieces. At Alcan Iceland and at 

Nordural, also in Iceland, the Stimir 

bath crusher is used to process bath 

emptied from spent anode transport 

trays. Bath is crushed to 200 to 250 

mm and is discharged to join the 

main bath conveyor from the anode 

cleaning machines. A similar crusher 

design is also available to pre-process 

large pieces of anode butt. 

mechatherm awarded furnace 

order for Balco expansion project 

Mechatherm has been awarded an 

order for 6 x 80 t capacity electrically 

heated tilting melting and holding 

furnaces for the new Balco expansion 

project in Korba, India. Through the 

help of Associated Industrial Furnaces 

(P) Ltd, Mechatherm finalised the 

deal which maintains its status as the 

No. 1 furnace supplier to the Vedanta 

group. Mechatherm is scheduled to 

complete installation and commissioning 

of the new furnaces during 

the middle of 2011. 

Ge receives Usd500m 

contract to supply 

GE Energy has received a contract 

of more than USD500m to supply 

equipment to power the world’s largest 

aluminium processing complex 

at a single site. The Emirates Aluminum 

(Emal) production facility is located 

close to the Arabian Gulf by Al 

Taweelah, Abu Dhabi, in the United 

Arab Emirates. 

renewable energy 

hat-trick for Hydro 

Hydro is planning the first groundbreaking 

for the Holsbru hydropower 

project this fall. In addition, 

the company has delivered a concession 

application for two hydropower 

projects in Sogn. Altogether, the three 

projects will increase Hydro’s power 

production by about 300 GWh. In addition 

to the Holsbru project, Hydro 

has applied for a concession to build 

a power plant at Øyane and a pump 

power plant at Ilvatn, both in the For- 


tun Valley in Sogn. The two plants will 

deliver 98 and 113 GWh, respectively, 

while Holsbru will increase the company’s 

power production by 84 GWh. 

Hydro is Norway’s second-largest 

producer of hydropower, with an average 

power production of 9.4 TWh a 

year, which it aims to increase by 10%. 

BHp and eskom sign an amendment 

for the mozal smelter 

Eskom and BHP Billiton have reached 

agreement on an amended power supply 

contract for the Mozal aluminium 

smelter in Mozambique. Discussions 

relating to the contracts for the supply 

of electricity to the Hillside and Bayside 

smelters in South Africa will continue 

with the intention of concluding 

binding agreements before the end of 

Eskom‘s 2010/11 financial year. 

With the announcement of this 

agreement, Eskom and BHP remain 

confident that, given the necessary 

time and commitment, innovative 

and mutually beneficial solutions will 

be found for the South African smelters. 

The smelters continue to make an 

important contribution to the South 

African economy and at present continue 

to fulfill a commitment to a 10% 

power reduction. The new pricing 

agreement will be submitted to the 

National Energy Regulator of South 

Africa for approval. ■ 

The author 

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

is founder of TS+C, Technical Info 

Services and Consulting, Sierre 

(Switzerland), a new 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 Alu Media GmbH in 

Düsseldorf, Germany. 

55

e s e a r c h 

a corrosion study of brazed aluminium 

heat exchangers after field service 

M. Melander & R. Woods 

Eleven sets of corroded heat exchangers 

have been examined. 

These were retrieved from cars 

which had been in service in 

Southern Sweden for two to ten 

years. The condensers suffered the 

worst corrosion, especially in the 

highly exposed basal areas. One 

radiator with AA3003 tubes and 

another fabricated from AA6000 

series alloys showed heavy external 

corrosion. All other radiators 

showed only light attack and 

internal corrosion was negligible 

except in the AA6000 series tubes. 

Of the nine evaporators received, 

two had copper tubes with aluminium 

fins while the remainder 

were all-aluminium. No evidence 

of corrosion was found. Of four 

charge air coolers examined, only 

one showed light corrosion. 

The automobile heat exchanger market 

worldwide is now dominated by 

the use of aluminium and the vast majority 

of units are brazed by the ‘Nocolok’ 

or CAB brazing process. Until 

10 to 15 years ago, vacuum brazing 

had been widely used and many such 

units are still in service. But, because 

of cost and process robustness considerations, 

CAB is now the predominant 

brazing process. In the early days 

of auto air conditioning, mechanically 

assembled condensers were used 

with salt bath, dip brazed aluminium 

evaporators. However, development 

of successful vacuum brazing operations 

triggered the move to this process 

for evaporators and opened up 

the opportunity to mass produce vacuum 

brazed aluminium radiators. As 

techniques improved some condensers 

were also produced using vacuum 

brazing. Whereas copper/brass heat 

exchangers had always had problems 

with the corrosive loss of solders in 

the tube/fin joints, early brazed aluminium 

units and especially radiators 

in use in ‘snow belt’ or coastal areas 

had severe intergranular and pitting 

corrosion attack of 

the tubes. 

In the early 

1980’s, gasoline 

shortages and rising 

prices initiated 

a drive in North 

America to dramatically 

reduce vehicle 

weights with 

consequent improvements 

in gas 

mileage. This concern 

over weight 

reduction and secondarily 

the desire to achieve material 

cost reductions both favoured 

the further adoption of aluminium as 

a replacement for copper/brass. But, 

the challenge of increasing the corrosion 

resistance of all aluminium heat 

exchangers remained. Progress was, 

however, made and by the mid-1980s 

several alternatives were available. 

An important factor in the evolution 

of the new long life materials was the 

early adoption of the SWAAT test 

(Sea Water Acetic Acid Test – ASTM 

G85) as an accelerated method for the 

laboratory evaluation of the external 

corrosion resistance of the products. 

Subsequently, accelerated laboratory 

testing and test track evaluations in 

North America showed that the ‘Brown 

Band’, or K319 type (in-house material 

designation by Kaiser Aluminum 

& Chemical Corp.) long life materials 

were extremely promising and field 

service has since proven this to be so. 

The corrosion mode is transformed 

from a heavy pitting or intergranular 

mode of attack in the AA3003/3005 

alloys, to a lateralised sub-surface 

form which greatly delays corrosion 

penetration through the tubes (Fig. 1). 

Other variants and improvements to 

this material followed quickly except 

in Asia where sacrificial systems have 

remained more popular. 

Although the automobile companies 

have conducted many field 

evaluations of aluminium component 

Fig. 1: A radiator with a ‘brown band’ long life type tube alloy 

after 5.5 years of field service 

performance, there is little information 

in the published literature. An extensive 

program examining five year 

radiator field retrievals was initiated 

by Ford in 1976. Results published 

in 1986 (Ref 1) showed that overall, 

vacuum brazed aluminium units performed 

better than both copper/brass 

and mechanically assembled aluminium 

radiators. Although the tube 

perforations found in the vacuum 

brazed units were cause for concern, 

the comparative results of this study 

were positive for brazed aluminium 

heat exchangers. A second study, this 

time of radiator field failures was published 

in 1992 (Ref 2). A total of 140 

failed copper/brass, mechanically assembled 

aluminium and aluminium 

vacuum brazed field retrievals were 

collected from the relatively aggressive 

Detroit area of the USA. Confirming 

the conclusions reached in Ref 1, 

the analysis showed that the failure 

rate of copper/brass units was three 

times that of the vacuum brazed aluminium 

radiators. Similarly, the mechanically 

assembled aluminium radiators 

had a 50% higher failure rate 

than vacuum brazed units. 

It was not until a later 1997 publication 

(Ref 3) that the performance of 

the so-called ‘long life’ vacuum brazed 

materials was included. In this study, 

the external corrosion resistance of 

units retrieved in Buffalo, another 

US ‘snow belt’ city, was shown to be 


Images: Sapa

Vehicle 

ID 

Year km 

remarkably improved by using these 

materials. Following ten years of field 

service, the most severe tube corrosion 

was limited to less than 40% of 

the tube thickness. As found in the 

earlier studies, units fabricated using 

standard AA3xxx series alloys had either 

perforated or been attacked beyond 

the mid-thickness of the tubes. 

In units retrieved from a less severe, 

but warm and saline coastal environment 

(Florida) the difference between 

standard alloys and the ‘long life’ variety 

was less dramatic. Essentially, 

all units examined were lightly but 

equally corroded. Noteworthy in all 

three studies was the near absence of 

internal corrosion. 

Much laboratory accelerated testing 

has been done on evaporators and 

condensers and the modes and extent 

of corrosion in this situation are well 

known in the industry. However, publications 

describing the field performance 

of heat exchangers other than 

the radiator are absent from the open 


Years in 

service life 

Evaporator Condenser 

Charge air 

cooler 

A 1992 260 000 10.5 x x 

B 1995 175 000 9 x x 

C 1997 205 000 7 x x 

L 1998 125 000 9.5 x 

K 1998 170 000 8.5 x 

E 1997 200 000 6.5 x x x 

F 1998 105 000 6.5 x x 

G 1998 180 000 5.5 x x 

H 1998 90 000 5.5 x x 

I 1999 198 000 5 x x 

J 1998 65 000 4 x x 

D 1998 384 000 2* x x x 

* Late in this study we learned that this car had first crashed in 2002 and the radiator had been 

replaced. Thus, the radiator, condenser and charge air cooler examined had seen only two years of 

service although the car had been in service for 6.5 years. 

Table 1: Heat exchangers collected 

literature. It was partly to redress this 

situation and partly to gather data on 

all heat exchanger performance in a 

Northern European environment that 

the present investigation was undertaken. 

Presentations of segments of 

this work have been given in Refs 4-7. 

collection of the heat exchangers 

The ten sets of heat exchangers were 

collected and sent to Sapa Technology 

by KIMAB (formerly the Swedish 

Corrosion Institute) from dismantling 

plants in the southern part of Sweden. 

The package collected included the 

radiator, evaporator, condenser and 

in a few cases the charge air cooler 

and oil cooler. One additional set from 

south central Sweden consisting of 

a radiator and a condenser was obtained 

by Sapa Technology during 

the course of this work. The parent 

vehicles are listed in Table 1 without 

identifying the specific manufacturers 

and models, together with the dif- 

r e s e a r c h 

ferent heat exchangers that were received. 

Some were from coastal areas 

and hence had been exposed to some 

degree of a marine environment while 

others were from inland areas where 

de-icing salts are routinely used during 

the winter months. The automobiles 

had between four and ten years 

of field service and had been driven 

between 65,000 and 380,000 kilometres. 

Late in this investigation we 

learned that one vehicle which had 

been in service for 6.5 years had been 

involved in an earlier accident and the 

radiator and probably the condenser, 

charge air cooler and oil cooler had 

been replaced. Thus, all those components 

had probably seen just two 

years of service. 

examination techniques and 

findings for external corrosion 

radiators 

Descriptive data for each of the radiators 

are shown in Table 2. 

Examination for external corrosion: 

The radiators were first examined 

visually and external corrosion 

of the tubes and fins appeared to be 

absent or only minor. Metallographic 

cross sections including the headerto-tube 

brazed joints and tube lengths 

of about 2.5 cm, revealed more attack. 

The corroded area visible in each of 

the 80-90 tube-fin fillets and about 25 

tube-header fillets was estimated and 

classified as being: a) Minor, less than 

25% of the joint missing b) Moderate, 

25% to 50% missing, or c) Severe, 

over 50% missing. Knowing the total 

number of joints examined, the percentage 

of joints falling into each ➝ 

Vehicle ID Tube core alloy (Brazing) Header core alloy Fin alloy Water side alloy 

A* AA6063 (VB) AA6063 AA6063 - 

B* 3005 LL-type (VB) AA6063 AA6063 - 

C 3005 LL-type (VB) AA6063 AA6063 AA3005 

D 3005 LL-type (CAB) AA3003 (AA3003 + Zn) AA7072 

E 3005 LL-type (VB) AA6063 AA6063 - 

F Al 0.8Mn 0.8Cu 0.2Mg Ti (CAB) Al 0.8Mn 0.6Cu AA3003 - 

G Al 1.2Mn 0.9Si Ti Cr (CAB) Al 0.7Mn 0.5Si 0.5Fe 0.5Cu AlFeNiZn Al 1.0Mg 1.0Zn 0.5Si 

H 3005 LL-type (CAB) Al 1.0Mn 0.4Si 0.5Cu (AA3003 + Zn) AA7072 

I Al 1.1Mn 0.6Cu 0.2Mg Ti (CAB) AA3003 AA3003 AA1050 

J AA3003 (CAB) AA3003 AA3003 + Zn AA7072 

L 3005 LL-type (CAB) AA3003 (AA3003 +Zn) AA3005 

* Radiators from A and B were painted 

Table 2: Probable radiator alloys and brazing method 

57

e s e a r c h 

Fig. 2: Corroded area fraction of tube-fin-fillets in radiators Fig. 3: Corroded area fraction of header-tube-fillets in radiators 

level of corrosion could be calculated. 

The results obtained are shown in bar 

chart form in Figures 2 and 3. 

In general, the same corrosion attack 

trends can be seen in both pairs 

of joints, i.e. very low braze joint corrosion 

in radiators L, G, H and D, 

very high in I, quite severe in E and 

moderate in the remainder. No real 

trend in fillet corrosion with increasing 

service life was evident. The depth 

of attack on the tubes was estimated 

in a similar way, with Figure 4 showing 

the number of attack sites in each 

depth group for each of the radiators. 

Tube attack was generally minimal 

and shallow again with no obvious 

trend to increased corrosion with 

increasing service life. The tailored 

composition radiator I (0.6 Cu, 0.2 Mg, 

0.09 Ti) from the Swedish west coast 

showed the most corrosion sites with 

some being very deep. But radiator F 

from Stockholm with a similar composition 

was very lightly corroded. 

Radiator A also from the west coast 

and manufactured from AA6XXX alloys 

had the longest service life and a 

large number of deep pits. Some tubes 

were fully perforated but had not 

leaked. The AA3003 unit (J) showed 

less attack than expected possibly being 

protected by the AA3003 + 1.7% 

Zn fins. However, we did not find 

evidence of tube protection from Zncontaining 

fins in the other radiators 

although protection of tube/fin and 

tube/header joints seemed probable. 

As a group, the CAB and vacuum 

brazed ‘brown band’ long life type 

alloys showed the least corrosion attack 

with only scattered, shallow corrosion 

sites. But surprisingly, these 

sites showed more IG and less lateral 

attack than was expected based upon 

historical laboratory SWAAT testing 

results. 

The intergranular mode of fin corrosion 

made quantification difficult. 

However, an attempt was made using 

a rating system with 0 = No or minor 

corrosion, to 4 = Very severe corrosion. 

There were some variations 

in the degree of fin corrosion at the 

different sampling positions within 

each radiator. So, the value shown in 

Figure 5 is a mean value of the corrosion 

estimates from at least three 

different locations. The fin corrosion 

was ‘moderate’ for all radiators and 

again no real trend in corrosion with 

increasing field service or alloy type 

was observed. 

Examination for internal corrosion: 

Samples including a length of 

header and measuring approx. 15x15 

cm square were cleaned and opened 

up for internal tube examination. A 

few sections showed some superficial 

crevice corrosion under the 

gasket ring but most were free from 

any evidence of general corrosion. 

Exceptions were the AA6063 radiator 

(A) which had a large number of 

pits some of which had almost penetrated 

completely through the tube 

and radiator H which had a scattering 

of very shallow pits. 

condensers 

All the extruded tubes were made 

from what was basically an AA1100 

type alloy and were zinc sprayed before 

assembly. Compositions varied 

slightly with some units containing 

up to 0.55% Fe. Condensers J and K 

had 0.43 and 0.31% copper respectively 

and K also contained 0.53% 

manganese. All the condensers had 

Fig. 4: Depth of attack in the radiator tubes Fig. 5: Fin corrosion in radiators 


een CAB brazed and all but unit I 

had been painted. Unit K had been 

chromate conversion coated before 

painting. Four of the units (A,E,F 

and G) showed moderate to heavy 

tube/fin de-bonding in the lower and 

more exposed part of the condensers 

(Fig. 6). Metallographic examination 

showed heavy braze fillet corrosion 

in these units. (Fig. 7). 

The upper and less exposed areas 

of the condensers showed much 

less fillet corrosion although this remained 

most severe in units A, E, F 

and G again. Unit B also showed severe 

lower and upper attack but fin 

de-bonding had not occurred. The 

replaced unit D with only about two 

years of service at the west coast was 

almost un-corroded as was unit L 

from central Sweden with 9.5 years 

of service but a low driving distance. 

There was no clear trend towards increased 

fillet corrosion with longer 

service lives. In general, fin corrosion 

was not heavy despite all the fins 

but K containing high levels of zinc 

(1.2-2.2%). Neither was there a trend 

towards increased fin corrosion with 


longer service times nor with increasing 

zinc content. As with the tube/fin 

fillets, tube corrosion was most severe 

in the bottom portions of the condensers. 

But, it was limited in all units to 

a maximum of 25% of the tube thickness 

being confined to a layer parallel 

to the tube surface – corresponding 

to the depth of inward diffusion of 

the zinc during brazing. Clearly the 

tube/fin fillets and not the fins were 

acting sacrificially to all the other 

components when the tubes were 

Zn coated. This behaviour has been 

predicted by laboratory SWAAT test 

programs. (Ref. 8) 

charge air coolers (cac’s) 

Only four of these (D, E, H and I) were 

collected with a maximum of 6.5 years 

of service and 200,000 kilometres of 

driving. All had been CAB brazed 

and were unpainted. Three were 

made from welded tubes and one (E) 

from extrusions. The core alloys were 

AA3XXX type with unit D containing 

0.48% Cu, and I containing 0.26% Cu 

and 0.24% Mg. All had Zn containing 

r e s e a r c h 

Fig. 6: Condenser with loose fins Fig. 7: Condenser fin de-bonding 

fins with contents ranging from 0.9% 

in I to 1.6% in H. 

External corrosion: Visually, no 

external corrosion was evident on 

any of the coolers. Metallographic 

samples were prepared and these 

showed that Unit H from south central 

Sweden with 5.5 years of service 

but only 90,000 kilometres showed no 

corrosion at all apart from some minor 

attack in the fins. Unit I was from 

the west coast and had clearly been 

fabricated using a long life type tube 

material. Overall it was moderately 

corroded showing the characteristic 

lateralised tube attack, shallow 

IG attack of the header and moderate 

attack of the fins, tube-to-fin and 

tube-to-header joints. A similar level 

of attack was found in unit D from the 

west coast but much more severe attack 

was present in E with five years 

of exposure, but which was fabricated 

with extruded tubes. This had pitting/ 

IG of the tubes (Fig. 8) and moderate 

to severe attack at all the other locations 

(Fig. 9). 

Internal corrosion: This, being an 

air-to-air heat exchanger some ➝ 

Fig. 8: Tube to fin joint corrosion in charge air cooler E Fig. 9: Extruded tube corrosion of charge air cooler E 

59

e s e a r c h 

internal corrosion corresponding to 

the heavy external corrosion seen 

in unit E, might have been expected. 

However, none was found in this or 

any of the other units. 

evaporators 

Of the nine evaporators collected 

two were with copper/brass tubes 

and AA1XXX aluminium alloy fins. 

The remainder were vacuum brazed, 

all-aluminium units, with AA3XXX 

alloy plates. Estimated copper levels 

varied between 0.06% and 0.45% with 

most between 0.25% and 0.45%. Manganese 

levels were over the range of 

0.62% to 1.2% and Mg contents varied 

from 0.16 to 0.45%. Titanium levels 

varied also, with two units containing 

approx. 0.02% and five units showing 

between 0.12% and 0.20% Ti. Five 

of the seven units were chromated. 

The fins were made from AA3005 or 

AA6XXX alloys. 

No external corrosion was visible. 

Metallographic cross-sections 

showed very light corrosion in the 

unprotected tank areas except for 

units D and J where a few instances 

of shallow intergranular attack were 

found. Evaporator J which had only 

four years of service and had been 

chromated, had the most attack 

sites. These were concentrated in the 

formed tank areas where some LFM 

(Liquid Film Migration) had occurred 

during brazing. The attack had not, 

however, proceeded through more 

than 25% of the plate thickness. No 

corrosion in the brazed joints was 

observed in any of these units. The 

fin corrosion seen in the sections was 

minor for all evaporators. 

Discussion 

As in previous heat exchanger studies 

(Refs 1, 2 and 3) the number of 

samples examined was very small 

compared to the total number of units 

in service. But as with those studies, 

we must assume that those collected 

were representative of the total population 

for the areas from which they 

were retrieved. Local environmental 

variations together with many other 

factors all introduce more and probably 

strong variables. Length of time 

in service was not a major factor in 

determining the extent of corrosion. 

But, if the population is considered 

as a whole, the levels of corrosion 

seen in this study were low; probably 

lower than expected and the general 

durability of the heat exchangers was 

very high. All the long life or ‘brown 

band’ welded tube radiators were in 

good condition and well in excess of 

ten years of service life should be confidently 

expected from these. The one 

radiator manufactured from AA6063 

alloy suffered badly from corrosion. 

Both external and internal corrosion 

were severe after 10.5 years and given 

that there were tube perforations, this 

unit was dangerously close to becoming 

a field failure. With the severity 

and generality of the corrosion found, 

the suitability of this alloy for any radiator 

application is very questionable. 

These findings corroborate the 

performance reported for AA6951 

alloy in Ref. 1. The other unit which 

showed significant external corrosion 

was an Al-1Mn-0.6Cu-0.2Mg-Ti tubed 

radiator protected only by AA3003 

fins. This showed severe external corrosion 

after only five years of service. 

Another radiator of similar tube composition 

and fins but from a different 

location, performed much better. This 

tends to support the suggestion that 

the environment may have been an 

important factor in the more corroded 

radiator. 

Metallographically, we found less 

severe external corrosion than generally 

reported in the previous North 

American studies. Results reported 

from Florida were close to those found 

here. Unexpectedly, we found more 

IG corrosion and less sub-surface lateral 

corrosion in the brown band type 

long term Swedish retrievals. This suggests 

that the 35 mv potential difference 

created in the sacrificial zone in 

these alloys is less effective in diverting 

corrosive attack in ‘mild’ service 

than it is during severe road service 

or in SWAAT testing. But, given the 

similarities in performance of all the 

heat exchangers to that observed in 

SWAAT, we remain satisfied that this 

is the most appropriate test for predicting 

performance in the field. 

As regards internal corrosion, this 

is only relevant to the radiators and 

we would expect units from Southern 

Sweden to have had well maintained 

coolant systems. In fact, only one radiator 

manufactured from AA6063 

alloy with deeply pitted tubes had any 

internal corrosion of note. This had 

seen nearly ten years of service and 

as reported in Ref 5 showed some evidence 

of chloride ions in the internal 

deposits on the tube, suggesting that 

tap water may have been used as a 

top-up thus contributing to the corrosion. 

With the other radiators, four 

of the ten investigated had Zn containing 

water side claddings, one of 

which showed some inconsequential 

shallow surface pitting. There was no 

evidence of the concentrated attack 

along the Zn-rich internal surface 

layer that is seen in OY-water, laboratory 

tested samples. 

In neither the radiators nor the 

condensers did the zinc containing 

fins show any level of increased corrosion 

over the zinc-free varieties. 

Correspondingly, we did not find evidence 

that the tubes were protected 

by these high zinc fins although there 

was evidence of mild protection to the 

radiator fin-to-tube fillets and to some 

degree the tube-to-header fillets. Certainly 

in the condensers the presence 

of zinc rich fins was overridden by the 

highly zinc enriched tube-to-fin fillets, 

the enrichment coming from the 

pre-braze zinc coating applied to the 

surface to protect the extruded tubes. 

This led to the alarming de-bonding of 

large portions of the cooling fins in the 

basal areas of some condensers. 

Brazed charge air coolers with 

welded tubes were also in good condition 

after up to 6.5 years of service. 

Heaviest corrosion was in the thicker 

walled extruded tube unit but none 

was close to a corrosion failure. CAC’s 

are usually positioned between the 

condenser and radiator and so have 

some measure of protection. 

conclusions 

• Two major areas of concern arising 

from these studies were: 

a) The occurrence of fin de-bonding 

in badly corroded condensers 

b) The poor performance of radiators 

fabricated from AA6063 alloy components. 


• None of the long life (brown band) 

type radiators showed significant external 

or internal tube corrosion. Ten 

years or more of service life can be 

confidently expected. 

• The situation with copper incorporated 

into the tubes to adjust the 

corrosion potentials is less clear since 

one of only two such radiators examined 

showed quite extensive external 

tube attack. 

• The zinc containing fins showed 

good sacrificial protection of the 

radiator tube-to-fin fillets without 

increased anodic consumption. Protection 

appeared to extend to the 

tube-to-header fillets. But these fins 

were ineffective in protecting tubeto-fin 

fillets in condensers. No real 

trend in either fin or tube corrosion 

with increasing field service time was 

observed. 

• No significant corrosion was found 

in the evaporators, oil coolers or 

charge air coolers. 

• No difference in corrosion performance 

between CAB and VB radiators 

was found. 

Patentblatt april 2010 

Fortsetzung aus ALUMINIUM 6/2010 

Aluminiumlegierung mit Nickel und 

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• Indications are that the prevailing 

conditions in the local operating 

environment are the most important 

factor affecting automobile heat exchanger 

corrosion rather than length 

of time in service. 

acknowledgments 

Thanks are due to Torkel Stenqvist, 

Lisa Abom, Anders Oskarsson and 

Stefan Norgren of Sapa for helpful 

discussions and Sapa Heat Transfer 

to supporting this work and permission 

to publish it. 

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➝ 

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aus einer Aluminium- 

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Strangpressprodukte der Aluminiumlegierung 

Al-Mn mit erhöhter mechanischer 

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Verfahren zur Wärmebehandlung von 

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Verfahren zur Herstellung eines Katalysatorkörpers 

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Verfahren zur Herstellung eines Leichtmetallverbundgussteils 

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Gewalztes Produkt. Aleris Aluminium 

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63

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DE. (B60R 9/04, GM 20 2007 001 742, 

AT: 07.02.2007) 

Dekoratives Bauteil. WKW Erbslöh Automotive 

GmbH, 42349 Wuppertal, DE. 

(B60R 13/04, GM 20 2007 002 233, AT: 

12.02.2007) 

Regenschutzschiene. Hermann Gutmann 

Werke AG, 91781 Weißenburg, 

DE. (E06B 1/34, GM 20 2008 014 277, 

AT: 27.10.2008) 

Fensterbankhalter. Hermann Gutmann 

Werke AG, 91781 Weißenburg, DE. 

(E06B 1/70, OS 10 2008 059 103, AT: 

26.11.2008) 

Silofahrzeug. Hydro Aluminium Deutschland 

GmbH, 51149 Köln, DE. (B60P 1/00, 

OS 198 45 573, AT: 02.10.1998) 

Verfahren und Vorrichtung zum Herstellen 

eines Aluminiumlegierungsverbundmaterials. 

Honda Giken Kogyo 

K.K., Tokyo, JP. (B22D 19/14, PS 195 39 

922, AT: 26.10.1995) 

Gebauter Kolben. Mahle International 

GmbH, 70376 Stuttgart, DE. (F02F 3/00, 

EPA 2173996, WO 2009/016089, EP-AT: 

24.07.2008, WO-AT: 24.07.2008) 

Kolben. Mahle König Kommanditgesellschaft 

GmbH & Co, 6830 Rankweil, 

AT. (F02F 3/24, EPA 2167806, WO 

2009/006650, EP-AT: 27.03.2008, WO- 

AT: 27.03.2008) 

Mehrteiliger Kolben für einen Verbrennungsmotor. 

Mahle International 

GmbH, 70376 Stuttgart, DE. (F02F 3/00 

u. F02F 3/22 , OS 10 2008 055 908 u. OS 

10 2008 055 909, AT: 05.11.2008) 

Vorrichtung und Verfahren zur Herstellung 

einer Metallfolie. Hydro Aluminium 

Deutschland GmbH, 51149 Köln, 

DE. (B21B 1/40, OS 10 2008 037 520, AT: 

06.11.2008) 

Mehrteiliger Kolben für einen Verbrennungsmotor 

sowie Verfahren zu 

seiner Herstellung. Mahle International 

GmbH, 70376 Stuttgart, DE. (F02F 3/22 

u. F02F 3/00, OS 10 2008 055 911 u. OS 

10 2008 056 203, AT: 05.11.2008 u. AT: 

06.11.2008) 

Zweiteiliger Kolben für einen Verbrennungsmotor. 

Mahle International 

GmbH, 70376 Stuttgart, DE. (F02F 3/00, 

OS 10 2008 058 190, AT: 20.11.2008) 

Mehrteiliger Kolben für einen Verbrennungsmotor 

sowie Verfahren zu seiner 

Herstellung. Mahle International GmbH, 

70376 Stuttgart, DE. (F02F 3/00 u. F02F 

3/22, OS 10 2009 032 865 u. OS 10 2009 

032 916, AT: 14.07.2009) 

Mehrteiliger Kolben für einen Verbrennungsmotor. 

Mahle GmbH, 70376 Stuttgart, 

DE. (F02F 3/00, PS 50 2004 009 393, 

EP 1660769, EP-AT: 19.08.2004) 

Einteiliger Kühlkanalkolben für einen 

Verbrennungsmotor. Mahle GmbH, 

70376 Stuttgart, DE. (F02F 3/22, PS 503 

11 581, EP 1546536, EP-AT: 19.09.2003) 

Hammervibrator für Stranggussvorgänge. 

Sumitomo Metal Industries, Ltd., 

Osaka 541-0041, JP. (B22D 11/128, EPA 

2174734, WO 2009/019969, EP-AT: 

18.07.2008, WO-AT: 18.07.2008) 

Aluminiumlegierungsplatte für das 

Pressformen. Sumitomo Light Metal 

Industries, Ltd., Minato-kuTokyo 105- 

8601, JP. (C22C 21/02, EPA 2169088, 

WO 2008/152919, EP-AT: 29.05.2008, 

WO-AT: 29.05.2008) 

Magnesiumlegierungsplatte. Sumitomo 

Electric Industries, Ltd., Chuo-kuOsakashiOsaka 

541-0041, JP. (C22C 23/02, 

EPA 2169089, WO 2009/001516, EP-AT: 

09.06.2008, WO-AT: 09.06.2008) 

Hartlötrippenmaterial für Wärmetauscher, 

Wärmetauscher und Verfahren 

zu dessen Herstellung. Denso Corp., 

Kariya, Aichi, JP; Sumitomo Light Metal 

Industries, Ltd., Tokio/Tokyo, JP. 

(B23K 35/28, OS 10 2007 028 139, AT: 

19.06.2007) 

Gießpulver für das Stranggießen und 

Verfahren zur Verwendung des Pulvers. 

Sumitomo Metal Industries, Ltd., 

Osaka, JP. (B22D 11/10, PS 698 09 659, 

EP 0899041, EP-AT: 26.08.1998) 

Patentblatt Juni 2010 

Al-Ti-Ru-N-C-Hartstoffschicht. Ceratizit 

Austria Gesellschaft m.b.H., 6600 Reutte, 

AT. (C23C 16/30, EPA 2179073, WO 

2009/003206, EP-AT: 26.06.2008, WO- 

AT: 26.06.2008) 

Material und Platte aus Al-Mg-Si-Legierung. 

Showa Denko K.K., Tokyo 105- 

8518, JP. (C22F 1/05, EPA 2184375, EP- 

AT: 28.02.2003) 

Al-Mg-Si-Legierungsblech, das ausgezeichnete 

Oberflächeneigenschaften 

aufweist und Herstellungsverfahren 

dafür. Kabushiki Kaisha Kobe Seiko Sho 

(Kobe Steel, Ltd.), Kobe-shi, Hyogo, JP. 

(C22C 21/08, PS 10 2004 013 497, AT: 

18.03.2004) 

Hochfeste Al-Zn-Legierung und Verfahren 

zum Herstellen eines solchen 

Legierungsprodukts. Aleris Aluminium 

Koblenz GmbH, 56070 Koblenz, DE. 

(C22C 21/00, OS 11 2004 000 596, WO- 

AT: 09.04.2004) 

Verfahren zur Herstellung einer Al-Ge- 

Legierung mit einer Wge-Polierstoppschicht. 

International Business Machines 

Corp., Armonk, N.Y., US. (H01L 23/532, 

PS 695 13 459,EP 0697730, EP-AT: 

05.07.1995) 

Elektrodenmaterial Cu-Al-Mg-Zn-Fe 

für Elektrolysevorrichtungen am biologischen 

Körper. Safetec GmbH, 88045 

Friedrichshafen, DE. (A61N 1/04, GM 20 

2007 003 523, AT: 07.03.2007) 

Verfahren zur elektrolytischen Beschichtung 

von Werkstoffen mit Aluminium, 

Magnesium oder Legierungen 

von Aluminium und Magnesium. Alotec 

Holding GmbH & Co. KG, 35708 Haiger, 

DE. (C25D 5/42, PS 503 03 610, EP 

1543180, EP-AT: 15.07.2003) 

Fortsetzung in ALUMINIUM 9/2010 


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 

� Exhaust gas treatment 

Abgasbehandlung 

Solios Carbone – France 

www.solios.com 

� Unloading/Loading equipment 

Entlade-/Beladeeinrichtungen 


www.flsmidthmoeller.com 


ALuMInA And pet COke SHIpunLOAderS 

Contact: Andreas Haeuser, ha@neuero.de 

1.3 Anode production 

Anodenherstellung 


L i e f e r v e r z e i c h n i s 

� Auto firing systems 

Automatische Feuerungssysteme 

rIedHAMMer GmbH 

D-90411 Nürnberg 

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

E-Mail: frank.goede@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 

� Mixing Technology for 

Anode pastes 

Mischtechnologie für Anodenmassen 


www.solios.com Buss AG 

CH-4133 Pratteln 

Phone: +41 61 825 66 00 

E-Mail: info@busscorp.com 

Internet: www.busscorp.com 

65


� 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: frank.goede@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 

� 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 

Could not find your 

„keywords“? 

Please ask for our 

complete 

„Supply sources 

for the 

aluminium industry“. 

E-Mail: 

b.schaefer@giesel.de 


� Furnace charging with 

molten metal 

Ofenbeschickung mit Flüssigmetall 



� Melting/holding/casting furnaces 

Schmelz-/Halte- und Gießöfen 

Gautschi 






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 






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 

67


� 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 



� 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 






complete 


for the 


E-Mail: 


� Dry absorption units for 

electrolysis exhaust gases 

Trockenabsorptionsanlage für 

Elektrolyseofenabgase 



� Tapping vehicles/Schöpffahrzeuge 



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 

1.15 Storage and transport 

Lager und Transport 

SMS Siemag Aktiengesellschaft 

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 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 





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 

2.1.1 Extrusion billet 

production 

Pressbolzenherstellung 




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 

� 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 




69


2.3 Section handling 

Profilhandling 

� Packaging equipment 

Verpackungseinrichtungen 

H+H HerrMAnn + HIeBer GMBH 

Fördersysteme für paletten 

und schwere Lasten 

Rechbergstraße 46 

D-73770 Denkendorf/Stuttgart 

Tel. +49 (0) 711 / 9 34 67-0 

Fax +49 (0) 711 / 3 46 0911 

E-Mail: info@herrmannhieber.de 

Internet: www.herrmannhieber.de 

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 






Tel. +49 (0) 711 / 9 34 67-0 

Fax +49 (0) 711 / 3 46 0911 



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 






Tel. +49 (0) 711 / 9 34 67-0 

Fax +49 (0) 711 / 3 46 0911 




GmbH + Co. kG 


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 



� Annealing furnaces 

Glühöfen 



� Heat treatment furnaces 

Wärmebehandlungsöfen 





� Custom designed heat 

processing equipment 

Kundenspezifische 

Wärmebehandlungsanlagen 



� 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 








Tel.: +31 315 641352 

Fax: +31 315 641852 




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 

2.8 Consultancy, 

expert opinion 

Beratung, Gutachten 

Dr.-Ing. Alexander Klaus, zert. Master Blackbelt 

Konrad-Adenauer-Str. 12, D-76877 Offenbach 

Tel.: +49 6348 247 67-0, Fax: 247 67-1 

E-Mail: mail@klausleansigma.de 

Internet: www.klausleansigma.de 


2.10 Machining of sections 

Profilbearbeitung 

� Processing of Profiles 

Profilbearbeitung 

tensai (International) AG 

extal division 

Steinengraben 40 

CH-4051 Basel 

Telefon +41 (0) 61 284 98 10 

Telefax +41 (0) 61 284 98 20 

E-Mail: tensai@tensai.com 

2.11 Equipment and 

accessories 

Ausrüstungen und 

Hilfsmittel 

� Inductiv heating equipment 

Induktiv beheizte 

Erwärmungseinrichtungen 

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 

� Ageing furnace for extrusions 

Auslagerungsöfen für 

Strangpressprofile 




Tel.: +31 315 641352 

Fax: +31 315 641852 




2.12 Services 

Dienstleistungen 

� Process improvement and 

cost reduction 

Prozessoptimierung und Kostensenkung 

Klaus LeanSigma 

Technologie & Ci für die Aluminiumindustrie 

see Consultancy, expert opinion 2.8 

71


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 


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 


Geschäftsbereich Aluminium 

Konstanzer Straße 37 

Postfach 170 

CH 8274 Tägerwilen 

Telefon +41/71/6666666 

Telefax +41/71/6666688 

E-Mail: aluminium@gautschi-engineering.com 

Kontakt: Stefan Blum, Tel. +41/71/6666621 

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 




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 

BSN Thermprozesstechnik GmbH 

see Heat Treatment 2.4 

� Annealing furnaces 

Glühöfen 

eBner Industrieofenbau Ges.m.b.H. 

Ruflinger Str. 111, A-4060 Leonding 

Tel. +43 / 732 / 68 68 

Fax +43 / 732 / 68 68-1000 

Internet: www.ebner.cc 

E-Mail: sales@ebner.cc 

Gautschi 



schwartz GmbH 





see Heat treatment 2.4 

� Bar heating furnaces 

Barrenanwärmanlagen 

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 



� Rolling mill modernisation 

Walzwerksmodernisierung 



� Spools / Haspel 



� Hot rolling units / 

complete plants 

Warmwalzanlagen/Komplettanlagen 



73


3.6 Cold rolling equipment 

Kaltwalzanlagen 





BSN Thermprozesstechnik GmbH � Heating furnaces / Anwärmöfen 

see Heat Treatment 2.4 Gautschi 



� Coil annealing furnaces 

Bundglühöfen 

Gautschi 




� Coil transport systems 

Bundtransportsysteme 


GmbH + Co. kG 





� Cold rolling units / 

complete plants 

Kaltwalzanlagen/Komplettanlagen 



� Drive systems / Antriebe 



� Process optimisation systems 

Prozessoptimierungssysteme 

Gautschi 



� Process simulation 

Prozesssimulation 

Gautschi 





� Roll exchange equipment 

Walzenwechseleinrichtungen 




GmbH + Co. kG 





� Rolling mill modernization 

Walzwerkmodernisierung 






� Slitting lines-CTL 

Längs- und Querteilanlagen 


� Strip shears 

Bandscheren 




� Trimming equipment 

Besäumeinrichtungen 




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 



� 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 






� Strip thickness measurement 

and control equipment 

Banddickenmess- und 

-regeleinrichtungen 

ABB Automation technologies AB 

Force Measurement 

S-72159 Västeras, Sweden 

Phone: +46 21 325 000 

Fax: +46 21 340 005 

E-Mail: pressductor@se.abb.com 

Internet: www.abb.com/pressductor 







� Strip flatness measurement 

and control equipment 

Bandplanheitsmess- und 

-regeleinrichtungen 

ABB Automation technologies AB 

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 







75


3.11 Coolant / lubricant 

preparation 

Kühl-/Schmiermittel- 

Aufbereitung 


� Rolling oil recovery and 

treatment units 

Walzöl-Wiederaufbereitungsanlagen 



� Filter for rolling oils and 

emulsions 

Filter für Walzöle und Emulsionen 





� Rolling oil rectification units 

Walzölrektifikationsanlagen 







3.12 Air extraction systems 

Abluft-Systeme 


� Exhaust air purification 

systems (active) 

Abluft-Reinigungssysteme (aktiv) 







� Filtering plants and systems 

Filteranlagen und Systeme 

dantherm Filtration GmbH 

Industriestr. 9, D-77948 Friesenheim 

Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 

E-Mail: info.de@danthermfiltration.com 

Internet: www.danthermfiltration.com 

3.14 Storage and dispatch 

Lagerung und Versand 




Bundlagersysteme 




GmbH + Co. kG 


3.17 Strip Processing Lines 

Bandprozesslinien 

� Colour Coating Lines 

Bandlackierlinien 

www.bwg-online.com 

see Strip Processing Lines 3.17 

� Lithographic Sheet Lines 

Lithografielinien 




� Stretch Levelling Lines 

Streckrichtanlagen 



� Strip Annealing Lines 

Bandglühlinien 



� 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 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 

4.3 Conveyor and storage 

technology 

Förder- und Lagertechnik 


GmbH + Co. kG 


4.5 Mold accessories and 

accessory materials 

Formzubehör, Hilfmittel 

� Fluxes 

Flussmittel 

Solvay Fluor GmbH 


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 


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 

ELPO GmbH 

Kuchengrund 18 

71522 Backnang 

Telefon 07191 9572-0 

Telefax 07191 9572-29 

E-Mail: info@elpo.de 

Internet: www.elpo.de 







Wärmebehandlungsöfen 



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 

77


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 


4.8 Handling technology 

Handhabungstechnik 


GmbH + Co. kG 


� Manipulators 

Manipulatoren 

4.9 Construction and Design 

Konstruktion und Design 

THERMCON OVENS BV 


� Mould parting agents 

Kokillentrennmittel 

Schröder kG 

Schmierstofftechnik 

Postfach 1170 

D-57251 

Freudenberg 

Tel. 02734/7071 

Fax 02734/20784 

www.schroeder-schmierstoffe.de 




see Extrusion 2 

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 




complete 


for the 


E-Mail: 


4.13 Melt operations 

Schmelzbetrieb 






� 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 






Gautschi 






Alu-web.de 

der ALUMINIUM- 

Branchentreff. 

Haben Sie schon Ihren 

Basiseintrag bestellt? 

Nein, 

dann sofort anrufen: 

0511/73 04-148 

Beate Schaefer 


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 




complete 


for the 


E-Mail: 


� Granulated aluminium 



4.15 Melt treatment devices 

Schmelzbehandlungseinrichtungen 

Metaullics Systems europe B.V. 

Ebweg 14 

NL-2991 LT Barendrecht 

Tel. +31-180/590890 

Fax +31-180/551040 

E-Mail: info@metaullics.nl 

Internet: www.metaullics.com 

4.17 Environment protection 

and disposal 

Umweltschutz und 

Entsorgung 

� Dust removal 

Entstaubung 

neOteCHnIk GmbH 

Entstaubungsanlagen 

Postfach 110261, D-33662 Bielefeld 

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

info@neotechnik.com, www.neotechnik.com 

� Flue gas cleaning 

Rauchgasreinigung 

dantherm Filtration GmbH 

Industriestr. 9, D-77948 Friesenheim 

Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 

E-Mail: info.de@danthermfiltration.com 

Internet: www.danthermfiltration.com 

Materials and Recycling 

Werkstoffe und Recycling 

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 

www.alu-web.de 

Hier könnte Ihr 

Bezugsquellen-Eintrag 

stehen. 

Rufen Sie an: 

Tel. 0511 / 73 04-148 


79


6 

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 



� Cleaning / Reinigung 



� Joining / Fügen 



� 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 

Could not find your „keywords“? 

please ask for our complete 

„Supply sources for the 


telefon: 

0511/7304-148 


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 

8 Literature 

Literatur 

� Technikcal literature 

Fachliteratur 

taschenbuch des Metallhandels 

Fundamentals of extrusion technology 


Hans-Böckler-Allee 9, 30173 Hannover 

Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157 

Internet: www.alu-bookshop.de 

� Technical journals 

Fachzeitschriften 


Hans-Böckler-Allee 9, 30173 Hannover 

Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157 


International 


Journal 

86. Jahrgang 1.1.2010 

Redaktion / Editorial office 

Dipl.-Vw. Volker Karow 

Chefredakteur, Editor in Chief 

Franz-Meyers-Str. 16, 53340 Meckenheim 

Tel: +49(0)2225 8359 643 

Fax: +49(0)2225 18458 

E-Mail: vkarow@online.de 

Dipl.-Ing. Rudolf P. Pawlek 

Fax: +41 274 555 926 

Hüttenindustrie und Recycling 

Dipl.-Ing. Bernhard Rieth 

Walzwerkstechnik und 

Bandverarbeitung 

Verlag / Publishing house 

Giesel Verlag GmbH, Verlag für Fachmedien, 

Postfach 5420, 30054 Hannover; 

Hans-Böckler-Allee 9, 30173 Hannover, 

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

E-mail: giesel@giesel.de 

Internet: www.alu-web.de. 

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Dennis Roß 

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layout 


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Der ALUMINIUM-Branchentreff des 

Giesel Verlages: www.alu-web.de 

ALUMINIUM · 7-8/2010 81

V O R S C H A U / P R E V I E W 

82 

IM NÄCHSTEN HEFT 

Special: ALUMINIUM 2010 

Vorberichte der internationalen Hütten- und Halbzeugindustrie, 

deren Ausrüstungspartner sowie der 

Aluminiumverarbeiter und Dienstleister anlässlich 

der Branchenmesse ALUMINIUM 2010 vom 14. bis 

16. September in Essen. 

Weitere Themen 

• Impol – einziger Aluminiumverarbeiter in 

Slowenien 

• SMS group – Ausrüster und Technologiepartner 

für die gesamte Aluminium-Wertschöpfungskette 

• Stranggussanlagen von Wagstaff – verlässliche Anlagentechnik 

seit 1946 

• Fortschrittliche Eintauchtechnik beim 

Einschmelzen von Fives Solios 

Sonstiges 

• Aktuelles aus der globalen Aluminiumindustrie 

Erscheinungstermin: 3. September 2010 

Anzeigenschluss: 20. August 2010 

Redaktionsschluss: 10. August 2010 

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IN THE NEXT ISSUE 

Special: ALUMINIUM 2010 

Preliminary reports from the international smelting 

and semis industry and their equipment partners as 

well as from aluminium processors and service providers 

in the run-up to the ALUMINIUM 2010 fair, 

from 14 to 16 September in Essen, Germany. 

Other topics 

• Impol – sole aluminium manufacturing company 

in Slovenia 

• SMS group – equipment and technology partner 

for the entire aluminium value chain 

• Wagstaff DC casting equipment – trusted source 

since 1946 

• Advanced submersion melting by Fives Solios 

Other topics 

• Latest international news from the aluminium 

industry 

Fax: +49 (0) 511 73 04 157 

Date of publication: 3 September 2010 

Advertisement deadline: 20 August 2010 

Editorial deadline: 10 August 2010 

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ALUMINIUM · 7-8/2010

The offi cial 

fair newspapers for 

Are you exhibiting 

at ALUMINIUM in 

Essen? 

If so, we have the ideal advertising 

medium for your message to the visitors 

and exhibitors at the world trade fair: 

APT Aluminium News = in English lish 

Aluminium Praxis = in German 

We are Offi cial Media Partner for the event and the September issues of those 

two titles are the only offi cial fair newspapers authorised by the organisers! 

Your advertising message reaches the fair’s visitors in several ways. The newspapers will be: 

� Sent in advance to all ALUMINIUM 2008 visitors 

� Laid out in the major hotels in and around Essen 

� Distributed at the entrances by special hostesses 

� Displayed at the trade press stand 

� If you want, displayed at your trade fair stand too 

And to crown it all: 

Both newspapers are being published with an increased print run of 

10,000 copies each – but with the same advertising rates! 

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Fax: +49 (0)511 7304-222 

E-mail: anzeigen@giesel.de 

NEWS 

�� 

�� 

�� 

Hydro set to grow 

as global aluminium 

company 2 

Aluminium makes 

new auto in roads 3 

Bhp Billiton investigate 

hydro-powered smelter 

plant in DRC 3 

Corus to sell European 

aluminium plants 4 

Higher electricity 

costs for Chinese 

smelters 5 

CONTRACTS 

Alcoa India facility 

for architectural 

products 8 

SOLIOS Environment 

wins EPC contract 

for QATALUM 9 

FE 

Official fair newspaper of 


■ Solartechnik Solartechnik gewinnt gewinnt an an Fahrt Fahrt durch durch eine eine Überschrift Überschrift die die hier hier nur nur als als Mustertext Mustertext dient dient 

Deutsche Deutsche Profilproduktion Profilproduktion boomt boomt 

Der Der boomende boomende Solarmarkt Solarmarkt 

birgt birgt für für die die AluminiumAluminiumindustrieindustrie 

und und das das verarverarbeitendebeitende Handwerk Handwerk gute gute 

Auftragschancen. Auftragschancen. Der Der leichte leichte 

Werkstoff Werkstoff dient dient als als Basis Basis für für 

zahl zahl reiche reiche Anwendungen: 

Anwendungen: 

Fassadenkonstruktionen, 

Fassadenkonstruktionen, 

leichte leichte und und haltbare haltbare StänStänderder für für die die Befestigung Befestigung von von 

Solarmodulen, Solarmodulen, ganze ganze DachDachanlagenanlagen oder oder LamelleneleLamellenelemente,mente, 

die die der der Gebäude Gebäude hülle hülle 

vorgesetzt vorgesetzt werden, werden, sind sind nur nur 

einige einige Beispiele. Beispiele. 

SS 

Giesel Verlag GmbH • Postfach 12 01 58 • 30907 Isernhagen • Deutsche Post AG • PVST H 41947 • Entgelt bezahlt 

Offizielle OOffizielle Messezeitung 

Messezeitung 

der dddddddddddder der der der der der der der de de d ALUMINIUM ALUM ALUM ALU AL AAA INIUM 2008 2008 

OFFICIAL OFFICIA OFFICIAL OFFICIA MEDIA MEDIA PARTNER PARTNER 

Hier steht ein Muster- 

text, text, der der ledigli lediglich dazu 

dient, dient, die die Optik Optik hier hier steht steht ein ein 

Mustertext Mustertext und und so weiter. weiter. 

olaranlagen haben sich in 

den letzten Jahren immer 

mehr zu klaren Favoriten 

in der privaten Energiegewinnung 

entwickelt. Gezielte und 

steigen de Energiekosten haben 

dazu si cher nicht unerheblich 

beigetragen. Neben der rationa- vate Haushalte in Deutsch- auf Siliziumbasis in elekt rische 

t heidung für saubere, land gewinnen mittlerweile Spannung um wandeln. Ei ne 

ih en Strom aus der Sonne, solche, nur zehn m 

bli 

2 olaranlagen haben sich in 

den letzten Jahren immer 

mehr zu klaren Favoriten 

in der privaten Energiegewinnung 

entwickelt. Gezielte und 

steigen de Energiekosten haben 

dazu si cher nicht unerheblich 

beigetragen. Neben der rationa- vate Haushalte in Deutsch- auf Siliziumbasis in elektrische entspricht. entspricht. Dass Dass Solarstrom Solarstrom in 

den letzten Jahren bis auf eine 

große, gesamtwirtschaftlich bedingte 

Modulfläche kann an ei nem Stagnation im Jahr 2002 stetig 

twa ein an Beliebtheit gewonnen hat, 

mweltfreundli- 

Chalco sees strong metals 

demand in China for next 10 years 

BEIJING - As rural 

China becomes 

wealthier ongoing 

demand for building 

materials will help 

China’s base metals 

demand stay strong 

for at least a decade 

more, the Chairman 

and CEO of Chalco 

said. 

Aluminum Corp of China, 

also known as Chinalco, 

is diversifying into copper, 

minor metals and rare 

earths to stabilize profits and 

capitalize on China’s continued 

growth, chairman Xiao 

Yaqing told reporters. 

“China’s economy consumes 

most of its 500 million 

tonnes of annual steel output, 

and base metals dem d 

should b 

6 billion tonnes of steel if its 

industrialization follows the 

same pattern as in Japan or 

the U.S. 

“So for the next ten-plus 

years, all base metals demand 

should stay strong.” Chinalc 

is adjustin 

�� 

�� 

OFFICIAL OFFICIAL MEDIA PARTNER 

�� 

into Yunnan Copper after 

buying a controlling stake in 

its parent this year. 


Chinalco i 

Hier steht ein Mustertext, der lediglich 

dazu dient, die Optik hier steht 

ein Mustertext und so weiter. Hier steht ein 

Mustertext, der lediglich... 

Putpat Putpat exero exero dignim dignim inciduis inciduis nullandre nullandre feu feu facil facil etum etum zzrit zzrit nullum nullum zzriure zzriure volore volore ecte ecte vulput vulput ut lore lore dolobor dolobor 

for smelters after this year 

would force the less innovative 

to close and prevent at 

least some of an estimated 4 

million tonnes of new capacity 

from starting up over the 

next two years. “I am relatively 

optimistic for aluminium 

prices. At the very least, 

they should retain this level 

due to the closures,” said 

Xiao, who also heads listed 

Aluminum Corp of China 

Ltd, or Chalco. Investments 

of US $399 million to US 

$532 million in upgrading 

products and reducing 

energy use, wastewater and 

greenhouse gas emissions is 

beginning to pay off. 

Chalco’s Ho 

Al 


30173 Hannover · Germany 

Tel. +49 511 7304-122 

Fax +49 511 7304-233 

www.giesel-verlag.de · vertrieb@giesel.de 

Inhalt Aus ga be 09 | 2008 

4. September 2008 | 11. Jahr gang 

Metallbau 

Metallbau 

BAU BAU 2005 2005 mit mit Schwerpunkt 

punkt Solartechnik Solartec . . . . . 2 

Zahlreiche Zahlreiche Innovationen 

Inn 

auf auf der der BAU BAU 2005 2 . . . . . . 2 

Aluminium Aluminium in industrie 

wächst wächst leicht leicht . . . . . . . . . . . 3 

Guss Guss 

Cobapress- Cobapress- 

Gießverfahren Gießverfahr . . . . . . . . . . 4 

Druckguss: Druckguss: Simulation 

spart spart Zeit Zeit und u Kosten. . . . 4 

Porträt Porträt DGS DGS 

Druckguss Druckguss Systeme AG . . 4 

AP-Gespräch: 

Metallbau 

Arvid Moss, 

Leiter Konzernbereich Metal Products 

Hydro Aluminium, Oslo: 

BAU 2005 mit Schwer- 

punkt Solartechnik . . . . . 2 

Zahlreiche Innovationen 

auf der BAU 2005 . . . . . . 2 

Aluminium industrie 

wächst leicht . . . . . . . . . . . 3 

Guss 

Cobapress- 

Gießverfahren . . . . . . . . . . 4 

Druckguss: Simulation 

spart Zeit und Kosten. . . . 4 

Porträt DGS 

Druckguss Systeme AG . . 4 

+ + + + www.alu-web.de + + + 

ir

Committed 

Committed 

to to the the future. 

future. 

Technology Technology partner partner for for the the aluminum aluminum industry. 

industry. 

Whatever Whatever it it is is that that you you want want to to produce produce – – as as your 

your 

technology technology partner partner in in plant plant construction, construction, we we strive 

strive 

to to make make even even the the impossible impossible possible. possible. This This reflects 

reflects 

our our commitment commitment to to the the markets markets of of the the future. 

future. 

A A constantly constantly evolving evolving spectrum spectrum of of new new product product ideas 

ideas 

requires requires innovation innovation and and adaptation adaptation in in plant plant design 

design 

and and construction. construction. Only Only a a partner partner with with expertise 

expertise 

covering covering the the entire entire aluminum aluminum production production process 

process 

can can deliver deliver real real solutions solutions here. here. Having Having recognized 

recognized 

the the importance importance of of mechatronic mechatronic know-how know-how early early on, 

on, 

Visit Visit us us at 

at 

ALUMINIUM ALUMINIUM 2010 

2010 

Hall Hall 3, 3, Booth Booth No. No. 3A40 

3A40 

September September 14 14 to to 16 

16 

Essen, Essen, Germany 

Germany 

we we are are always always ready ready to to implement implement the the latest latest develdevelopmentsopments 

in in aluminum aluminum production production and and processing. 

processing. 

As As part part of of our our X-Pact X-Pact technology technology and and automation 

automation 

packages, packages, all all functional functional and and operating operating simulations 

simulations 

are are thoroughly thoroughly tested. tested. Especially Especially in in plant plant revamp revamp and 

and 

conversion conversion projects, projects, this this results results in in highly highly improved 

improved 

ramp-up ramp-up times. 

times. 

The The evolution evolution of of aluminum aluminum – – SMS SMS Siemag. 

Siemag. 

MEETING MEETING your your EXPECTATIONS 

EXPECTATIONS 

SMS SMS SIEMAG SIEMAG AG 

AG 

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

communications@sms-siemag.com 

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

www.sms-siemag.com

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