special - ALU
Transcription
special - ALU
OFFICIAL INTERNATIONAL MEDIA SPONSOR Special 2008 The international smelting industry Zero fuel baking – the total heat recovery concept Auto control system for quality casting Norsk Hydro Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-web.de – PVST H 13410 – Dt. Post AG – Entgelt bezahlt OFFICIAL MEDIA PARTNER Ebner: demanding heat treatment applications Volume 84 · January / February 2008 International Journal for Industry, Research and Application 1/2 Billets ready for shipment. Continuous Homogenizing Plant. Continuous Homogenizing Plant Continuous Homogenizing Plant. We will exhibit at: TMS 2008 137th Annual International Meeting & Exhibition Booth No. 708 March 9 to 13 New Orleans, Louisiana, USA Leading technology in the aluminum casthouse. There are many benefits in one-stop shopping – even for industrial goods. Reliable, cooperative planning, specifications, which meet exactly your demands and individual service-packages to operate on first-class level throughout the whole lifetime of the plant – this can be realized by one of the most experienced suppliers: Hertwich Engineering. Major benefits Hertwich Engineering is dedicated to leading technology in the aluminum casthouse. We add value by designing integrated turnkey solutions. From melting and remelting to testing and packing. The results are convincing: highest quality of products at lowest cost-of-ownership. This has been proven by numerous plants all over the world. Continuous Homogenizing Plant Reliable, maximum homogenizing quality, uniform for all billets Lowest labour costs, full automation Best log straightness, no deep surface marks Extremly reliable operation, little down-time, low repair costs Lowest energy consumption, low power ratings Flexibility of plant layout More than 80 plants in operation MEETING your EXPECTATIONS HERTWICH ENGINEERING GMBH Weinbergerstrasse 6 5280 Braunau, Austria Phone: +43 (0) 7722 806-0 Fax: +43 (0) 7722 806-122 E-mail: [email protected] Internet: www.hertwich.com EDITORIAL Volker Karow Chefredakteur Editor in Chief Die Aluminiumindustrie im Sog der Globalisierung The aluminium industry in the wake of globalisation ALUMINIUM · 1-2/2008 Die Globalisierung von Wirtschaft, Politik und Kultur ist in aller Munde. Neu ist das Phänomen wahrlich nicht, man denke nur an den einzigartigen Aufstieg der Fugger-Dynastie im 15./16. Jahrhundert, der auf der Entwicklung eines internationalen Handels- und Bergbaugeschäftes gründete. Zweifellos nehmen sich diese frühen Ausprägungen der „Globalisierung“ bescheiden aus, verglichen mit denen unserer Zeit. Interessant ist der historische Rekurs dennoch: sind es doch gerade in jüngster Zeit die Rohstoffkonzerne, die wieder ins Blickfeld des Wirtschaftsgeschehens geraten, die zudem weltumspannend agieren und zu den höchst bewerteten zählen. Auch die Aluminiumindustrie ist in diesen Globalisierungstrend einbezogen – sowohl durch die Stoffströme vom Bauxitabbau über die Metallproduktion bis hin zur Vermarktung der Endprodukte als auch durch den Konzentrationsprozess, der auf Unternehmensebene stattfindet und bei dem es die internationalen Minengesellschaften sind, die derzeit das Spiel diktieren. Dabei zeigt sich, dass es entlang der Wertschöpfungskette in der Aluminiumbranche durchaus unterschiedliche Ausprägungen und Arten der Globalisierung gibt. Je nach den spezifischen Wettbewerbsfaktoren und Marktbedingungen sind ihre treibenden Impulse bei Hüttenbetrieben andere als bei Halbzeugwerken oder in der Endfertigung, wenngleich das Streben nach Wachstum und Gewinnmaximierung schlussendlich bei allen gleich ist. Welche wirtschaftlichen Triebkräfte hinter der Globalisierung stehen, welchen Veränderungen die Branche in Zukunft ausgesetzt sein wird, ob integrierte Aluminiumkonzerne ein Auslaufmodell sind und kleine und mittlere Unternehmen eine Überlebenschance in einer globalisierten Wirtschaftswelt haben – diesen Fragen geht ein Beitrag von Bruno Rüttimann in dieser und der nächsten Ausgabe der ALUMINIUM nach, auf den an dieser Stelle besonders hingewiesen sein soll. Er bildet das Pendant zu einem Überblicksartikel über die Branchenaktivitäten des letzten Jahres nebst einer Reihe technisch orientierter Beiträge von namhaften Technologiepartnern und Ausrüstern der Branche, die sich im Hütten-Special wiederfinden. Globalisation of the economy, politics and culture is taking place all over the world. True, the phenomenon is not new: one need only think of the unprecedented rise of the Fugger dynasty in the 15th and 16th centuries, which was based on the development of an international trading and mining business. But there is no doubt that those early forms of ‘globalisation’ were modest compared with what is happening in our own times. Still, the historical precedent is interesting: in very recent times it is precisely the raw materials concerns which are again at the focus of economic interest, which moreover are active across the world, and which are among the most highly valued. The aluminium industry too is involved in this globalisation trend – both due to the material flows from bauxite mining, through metal production and up to the marketing of end products, and also due to the concentration process that has been taking place at corporate level and in which it is the mining concerns which now call the shots. In this, it is evident that along the value-addition chain in the aluminium industry there are quite different forms and types of globalisation. In accordance with the specific competition factors and market conditions, the driving impulses for smelter operation are different from those of semis plants or for finished-goods production, even though the striving for growth and maximum profits is ultimately common to them all. What are the economic driving forces behind globalisation, what changes will the branch be exposed to in times to come, are integrated aluminium concerns an outmoded concept and do small and medium-sized enterprises have a chance to survive in a globalised economic world? These questions are dealt with in a contribution by Bruno Rüttimann in this and the next issue of ALUMINIUM, to which particular reference is made at this point. It forms the pendant to a review article on the branch activities of last year, besides a series of technically orientated contributions by noted technology partners and equipment suppliers of the aluminium branch, to be found in the Special on smelting. 3 I N H A LT EDITORIAL Die Aluminiumindustrie im Sog der Globalisierung ....................... 3 A KT U E L L E S Personen, Unternehmen, Märkte ............................................ 6 WIRTSCHAFT 28 Englischsprachige Artikel: s. nebenstehendes Verzeichnis Aluminiumpreise .............................................................. Produktionsdaten der deutschen Aluminiumindustrie .................. ECCA: Produktion von beschichtetem Aluminiumband legt erneut zu Otto Rudolf Fuchs begeht 80. Geburtstag ................................ EEG-Ausgleichsregelung für stromintensive Betriebe: Ersparnisse von mehr als einer halben Milliarde Euro ................................ 12 14 25 27 28 S P E C I A L 2 0 0 8 : D I E I N T E R N AT I O N A L E ALUMINIUM-HÜTTENINDUSTRIE Englischsprachige Artikel: s. nebenstehendes Verzeichnis ............. 30 M A R KT U N D T E CH N I K 48 Englischsprachige Artikel: s. nebenstehendes Verzeichnis Ebner Industrieofenbau: Anspruchsvolle Anwendungen bei der Wärmebehandlung / Interview mit der Geschäftsführung ........ 66 Siemens liefert Fertigstraße für Aluminium-Walzwerk nach China ... 73 U M W E LT U N D Ö K O L O G I E Friedensnobelpreis für IPCC: Ein Quäntchen Ehre auch für Halvor Kvande ................................................................. 79 BDI-Studie: CO 2 -Reduzierungspotenzial in NE-Branche nur zu Lasten der Wettbewerbsfähigkeit möglich ............................... 82 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 ................... 83 56 FORSCHUNG Englischsprachige Artikel: s. nebenstehendes Verzeichnis Entstehung von CO 2 -Emissionen bei der Herstellung von Aluminium-Walzprodukten vor dem Hintergrund des nationalen Emissionshandelssystems ................................................... 96 V E R A N S TA LT U N G E N RWTH Seminar: Einführung in die Technologie des Aluminiums .... 102 Termine, Fortbildung ........................................................ 103 D O K U M E N TAT I O N 64 Neue Bücher .................................................................. 100 Literaturservice ............................................................... 105 Patente ........................................................................ 108 Impressum .................................................................... 129 Vorschau....................................................................... 130 STELLENANGEBOT ............................................................... 89 Der ALUMINIUM-Branchentreff des Giesel Verlags: www.alu-web.de 4 B E Z U G S Q U E L L E N V E R Z E I C H N I S . . . . . . . . . . . . . . . . . . . . . . . . . 112 ALUMINIUM · 1-2/2008 CONTENTS EDITORIAL The aluminium industry in the wake of globalisation .................... 3 NEWS IN BRIEF People, companies, markets . . . . . . . . . . . . . . . . . . . ............................... 7 ECONOMICS Which globalisation for the aluminium industry? – Part I ............. Marubeni predicts aluminium surplus in 2008 ........................... Rio’s outlook for metals and minerals . . . . . . . . ............................. China sets guidelines for domestic aluminium and alumina projects ECCA: production of strip-coated aluminium gains new momentum 16 23 23 24 25 66 S P E C I A L 2 0 0 8 : T H E I N T E R N AT I O N A L A L U M I N I U M S M E LT I N G I N D U S T R Y Primary aluminium activities at the turn of the year 2007/08 ........ Self-lifting crane modernizes older potlines . ............................. Hydraulic pressing of prebaked anodes for aluminium smelters ...... Zero fuel baking – the total heat recovery concept .................... Best available technology for the fume treatment of anode production plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. New generation of FLSmidth Möller direct pot feeding system ...... Metal treatment update . . . . . . . . . . . . . . . . . . . . . . . . ............................. Auto control system for quality casting . . . . . . ............................. History of intensive mixing for anode paste used in aluminium electrolysis . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. 30 39 40 44 48 54 56 61 This issue contains an enclosure from 64 Reed Exhibitions Deutschland GmbH M A R K E TS A N D T E CH N O LO GY Ebner Industrieofenbau: Demanding heat treatment applications / Interview with Ebner management board .................................... 66 Siemens supplies new aluminium foil finishing mill .................... 73 Aluminium for building and construction in China ...................... 74 European Aluminium Renovation Award 2007 .......................... 77 Inserenten dieser Ausgabe E N V I R O N M E N T A N D E CO LO GY Articles in German, see index of contents on the left Nobel Peace Prize for IPCC: a small slice of glory also for Halvor Kvande .......................................................................... 79 C O M PA N Y N E W S W O R L D W I D E Aluminium smelting industry . . . . . . . . . . . . . . . . . . ............................. Bauxite and alumina activities . . . . . . . . . . . . . . . . . ............................. Recycling and secondary smelting . . . . . . . . . . . . ............................. Aluminium semis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. Suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. 83 85 86 88 91 RESEARCH Articles in German, see index of contents on the left Multi-temperature measurement of thermoelectric power for character isation of solute levels in multi-component industrial aluminium alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. 92 EVENTS Review: Incal 2007 – 3 rd International Conference on Aluminium .. 102 Dates . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 103 D O C U M E N TAT I O N New books . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 100 Literature service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 105 Imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 129 Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 130 J O B A D V E R T I S E M E N T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 S O U R C E O F S U P P LY L I S T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ALUMINIUM · 1-2/2008 to which we draw your kind attention. List of advertisers ABB Switzerland Ltd., Schweiz 31 Alcutec Engineering GmbH 37 Almeq Norway A.S., Norwegen 65 Böhler Edelstahl GmbH & Co. KG, Österreich 47 Buss ChemTech AG, Schweiz 55 Coiltec Maschinenvertriebs GmbH 75 Drache Umwelttechnik GmbH 33 Edimet S.p.A., Italien 11 El-Net Consulting AG – Stellenangebot 89 Gesamtverband der Aluminiumindustrie e.V. 23 Glama Maschinenbau GmbH 13 Haarmann Holding GmbH 69 Hertwich Engineering GmbH, Österreich 2 High Performance Industrie-Technik GmbH, Österreich 57 Innovatherm Prof. Dr. Leisenberg GmbH & Co. KG 53 Inotherm Industrieofen- und Wärmetechnik GmbH 22, 82 Lucky-Winsun Enterprise Co., Ltd., Taiwan 63 Maschinenfabrik Gustav Eirich GmbH & Co. KG 43 O.M.S. Impianti Srl, Italien 49 Padelttherm GmbH 67 Reed Exhibitions Deutschland GmbH 21 Reed Exhibitions India 29 Seco/Warwick S.A., Polen 59 Shanghai Jieru Heavy Industry Equipment Co. Ltd., China 35 SMS Demag AG 132 5 AKTUELLES Hamburger Trimet-Hütte wieder unter Vollauslastung Anfang Januar dieses Jahres konnte Günter Kirchner, Geschäftsführer und Vorstandsmitglied des Verbandes der Aluminiumrecycling-Industrie e.V. (VAR), Düsseldorf, auf eine 25-jährige Tätigkeit für den Verband blicken. Der gelernte Jurist und Rechtsanwalt wechselte 1983 zur damaligen Vereinigung der deutschen Schmelzhütten (VDS), nachdem er zuvor drei Jahre als Geschäftsführer des Vereins deutscher Metallhändler (VDM) sein “Handwerk“ in der Welt der NE-Metalle erlernt hatte. Seit 24 Jahren ist Kirchner außerdem als Generalsekretär in der Organisation of European Aluminium Refiners and Remelters (OEA) tätig. Die Redaktion ALUMINIUM gratuliert. Foto: Scheben Günter Kirchner feiert VAR-Jubiläum Seit Ende 2007 wieder mit voller Kapazität unterwegs – die Trimet-Hütte in Hamburg Schneller als angekündigt arbeitet die Hamburger Aluminiumhütte der Trimet Aluminium AG wieder unter Volllast. Am 14. Dezember 2007 wurde der letzte der 270 Elektrolyseöfen in Betrieb genommen. Damit hat das Werk seine ursprüngliche Kapazität von 130.000 Tonnen Primäraluminium im Jahr erreicht. Die Produktion der ersten Öfen war am 9. Mai 2007 feierlich gestartet worden. Am 1. Dezember 2006 hatte die Trimet das stillgelegte Werk von Hydro übernommen. Im Jahresverlauf wurden 250 Mitarbeiter eingestellt. 2008 will Trimet am Hamburger Standort 25 Mio. Euro in die Modernisierung der Anodenfabrik investieren. Dort wird ein neuer Brennofen mit größerer Kapazität in Betrieb gehen, der die Versorgung der Hütte mit Anoden sicherstellen wird. Auch der Standort Essen, wo Trimet eine weitere Aluminiumhütte betreibt, wird dann von Hamburg aus beliefert werden. EU plant Emissionshandelspflicht für NE-Metallindustrie Die EU-Kommission beabsichtigt, das europäische Emissionshandelssystem (ETS) auf andere Treibhausgase neben CO2 auszudehnen und zusätzliche Industriebranchen in den Emissionshandel aufzunehmen. Dazu zählt auch die Erzeugung und Bearbeitung von NE-Metallen. So sollen die Produktion von Aluminium (primär und sekundär) und die Erzeugung und Bearbeitung von NE-Metallen einschließlich Gießereien ab 2013 der Emissionshandelspflicht unterliegen. Konkret werden voraussichtlich nur Anlagen von mindestens 20 MW thermischer Leistung betroffen sein. Bei Anlagen der Aluminiumindustrie sollen zusätzlich zum Kohlendioxid die perfluorierten Kohlenstoffe (PFC) handelspflichtig werden. Mit der Integration in den Emissionshandel wäre für die deutsche Aluminiumindustrie eine zusätzliche Kostenbelastung verbunden, die im internationalen Wettbewerb nicht auf die Kunden überwälzt werden kann. Die EU-Kommission sieht die Integration der NE-Metalle in den Emissionshandel als einen Lösungsweg, um einen Ausgleich für den Strompreiseffekt des Emissionshan- 6 dels zu schaffen. Dazu müssten jedoch stromintensive Prozesse wie die Erzeugung von Primäraluminium ein Vielfaches ihrer direkten CO2-Emissionen kostenlos zugeteilt bekommen, um einen vollständigen Ausgleich für die Einpreisung der CO2-Zertifikate in den Strompreis zu erreichen. Zu Jahresbeginn hat die EU-Kommission bei der Kompensation des Strompreiseffektes einen Rückzieher gemacht. Der betreffende Passus über die kostenlose Überzuteilung von Zertifikaten an stromintensive Branchen, die im internationalen Wettbewerb stehen, wurde aus dem Entwurf der Emissionshandelsrichtlinie gestrichen. Auch die Idee, mittels einer Besteuerung an der EU-Außengrenze den Produktionskostennachteil innerhalb der EU für Aluminium und andere energieintensive Produkte auszugleichen, hat die EU unter Vorbehalt gestellt. So ist vor dem Start der dritten Phase des Emissionshandels eine Prüfung vorgesehen, ob ein erhebliches Risiko der Abwanderung von energieintensiven Branchen infolge der Kostensteigerungen des Emissionshandels zu erwarten ist. Für die Planungs- und Investitions- sicherheit der gesamten NE-Metallindustrie ist es unabdingbar, bereits heute die Wettbewerbsfähigkeit durch geeignete Maßnahmen zu sichern und diese in der Emissionshandelsrichtlinie zu verankern. Gemeinsam mit Eurometaux, dem europäischen Dachverband der NE-Metallindustrie, fordert die WVM zu allererst eine wirksame Kompensation des Strompreiseffektes. Dies könnte durch drei Optionen geschehen: • die kostenlose Zuteilung von Zertifikaten direkt an energieintensive Unternehmen • die kostenlose Weitergabe der Zertifikate an energieintensive Unternehmen im Rahmen von Langfristverträgen mit der Energiewirtschaft • die Rückvergütung von Auktionserlösen an energieintensive Unternehmen. Ende Januar 2008 (Anm.: nach Redaktionsschluss) legt die EU-Kommission ihren Vorschlag zur Fortsetzung des Emissionshandels ab 2013 vor. Wie bereits im Vorfeld wird sich die WVM gemeinsam mit den europäischen Verbänden in Brüssel und Berlin für eine Kompensation des Strompreiseffektes einsetzen. Michael Niese, WVM ALUMINIUM · 1-2/2008 NEWS IN BRIEF Alcoa sells packaging and consumer businesses to New-Zealand’s Rank Group • Reynolds Food Packaging, a business for products, services and solutions that improve performance in the catering, deli, bakery, vending and produce industries. Photo: Alcoa Alcoa has agreed to sell its packaging and consumer businesses for US$2.7 billion in cash to New Zealand’s Rank Group Ltd. The transaction is expected to be completed by the end of the first quarter 2008. The sale includes: • Closure Systems International, a global manufacturer of plastic and aluminium packaging closures and capping equipment for beverage, food and personal care customers; • Consumer Products, a leading manufacturer of Reynolds Wrap branded and private label foil, wraps and bags; • Flexible Packaging, a manufacturer of laminated, printed, and extruded non-rigid packaging materials such as pouch, blister packaging and foil lidding for the pharmaceutical, food and beverage markets; tries around the world and generated US$3.2 billion in revenues and US$95 million in after-tax operating income in 2006, representing approximately ten percent of the company’s revenues and three percent of its after-tax operating income. Alcoa will continue to operate its flat-rolled can sheet products serving the packaging market. Rank Group is a New Zealand-based privately owned company with a significant packaging presence, including: Carter Holt Harvey, SIG Holding, and Evergreen Reynolds Wrap – soon belonging to Rank Group Packaging. Rank Group has worldwide operations and emThese packaging businesses have ploys approximately 17,000 people. some 10,000 employees in 22 coun- With buy-out of Alcan by Rio Tinto, is Kitimat smelter dead? Questions are being raised about Rio Tinto Alcan and its ability to construct a new smelter in Kitimat given the huge debt Rio Tinto has amassed in the Alcan buy-out. After all, Rio Tinto has paid a 33% premium for the Alcan shares in the US$38.1bn takeover. Tom Albanese, who was formerly Alcan’s chief but then moved to Rio Tinto, finds himself with a debt load of about US$47bn. Rio Tinto will sell some Alcan divisions to yield about US$8bn, leaving a debt of US$39bn which still will eat up a staggering US$2bn a year in interest alone. Industry experts say that in order for the deal to work, long term aluminium prices need to be about US$2,770 a tonne. However, the current spot price is about US$2,530 per tonne, and analysts point out that the long term price will be around US$1,870 per tonne. That is, of course, unless Rio Tinto is able to freeze up the supply and drive up the price of the product; but that does not seem likely. Now, what effect will this latest move have on the dark clouds that ALUMINIUM · 1-2/2008 have hung around Kitimat for years? If Rio Tinto wants to snare some big money, it could sell its power producing facilities to another source. That would free up needed cash. The company could (in order to get the cash flow going) simply shut down the Kitimat smelter as a way to reduce the source of product and simply sell power to the BC Hydro grid that hands them a tidy cash flow. They could also go ahead with the new smelter, but that requires investing US$2b and the question is, where does the money come from? Realisation of the Kitimat smelter is becoming less and less likely as Rio Tinto takes control of Alcan and looks to see from where it can milk some much needed cash. paw Based on Aluminum Association surveys, U.S. primary aluminium production totalled 2.56 million tonnes in 2007, an increase of 12.2 percent over the 2006 total of 2.28 million tonnes. 7 AKTUELLES FORMWERK aktuell Evonik verkauft Rütgers Chemicals Mit neuem Konzept und Chefredakteur Die Evonik Industries AG verkauft ihre Tochtergesellschaft Rütgers Chemicals an den Finanzinvestor Triton. Mit dem Abschluss der Transaktion wird im 1. Quartal 2008 gerechnet. Rütgers Chemicals, ein international tätiges Unternehmen der Basischemie, ist Europas führender Hersteller von Erzeugnissen der Teerchemie sowie globaler Rohstofflieferant der Aluminium- und Stahlindustrie. 2006 erzielte das Unternehmen einen Umsatz von 650 Mio. Euro, das operative Ergebnis lag bei rund 60 Mio. Euro. Für 2007 wird ein Umsatz von rund 700 Mio. Euro erwartet. Rütgers beschäftigt derzeit weltweit 950 Mitarbeiter und produziert in Europa sowie Nordamerika an acht Chemiestandorten. Am Firmensitz in Castrop-Rauxel wird die weltweit größte Raffination von Steinkohlen- Wolfgang Bahle (48) hat zum 1. Januar 2008 die Chefredaktion der im Giesel Verlag erscheinenden Fachzeitung FORMWERK aktuell übernommen. Bahle kommt vom Carl Hanser Verlag, München, wo er seit 2003 die Redaktion des Magazins Form + Werkzeug leitete. „Mit Wolfgang Bahle haben wir einen anerkannten Fachjournalisten gewonnen, der sich in der Branche bestens auskennt und über mehr als zwei Jahrzehnte Erfahrung als Macher von Fachmedien verfügt“, betont Dietrich Taubert, Herausgeber von FORMWERK aktuell. Bahle wird die Fachzeitung mit eigenem Redaktionsbüro von München aus betreuen. Nach der Übernahme hat der Giesel Verlag den Titel komplett umstrukturiert. Mit der Berufung Bahles zum Chefredakteur ist diese Phase nun abgeschlossen. „Aus vielen Magazinen haben wir eine aktuelle Fachzeitung für den Formen- und Werkzeugbau gemacht, die das Fachzeitschriften-Portfolio unseres Hauses ideal ergänzt“, erläutert Taubert das neue Konzept. Der Giesel Verlag verfügt als Herausgeber renommierter Branchentitel wie der K-Zeitung, Automotive Materials und Aluminium Praxis etc. über ein Industrienetzwerk und Branchen-Knowhow, das für den Auf- und Ausbau von FORMWERK aktuell beste Voraussetzungen bietet. Im Zeitungsformat (A3) stellt sich das Fachblatt nach dem Relaunch nicht nur optisch im neuen Gewand dar, sondern wird auch inhaltlich mit einem noch breiter gefächerten Themenangebot aufwarten. Im Vordergrund stehen Nachrichten und Fachberichte aus der Welt des Formen- und Werkzeugbaus: von der Produktentwicklung über den Werkzeug- und Formenbau bis hin zum Serienbeginn. Für 2008 sind sechs Ausgaben mit einer Auflage von jeweils 12.000 Exemplaren geplant. Die erste Ausgabe startet im März. Zu den Abonnenten von FORMWERK aktuell gehören Entscheider aus dem Form- und Werkzeugbau sowie aus den Branchen Kunststoff, Stahl, NE-Metalle, Automotive, Medical und Composite. 8 teer betrieben, weitere Anlagen stehen in Belgien und Kanada. Im Geschäftsfeld Aromatics werden unter anderem Peche für die Aluminiumund Stahlindustrie produziert. Wachstumschancen sieht das Unternehmen in Asien, Brasilien und Russland. Triton ist eine unabhängige Private Equity Gesellschaft, deren Investmentstrategie auf Unternehmen in deutschsprachigen und nordischen Ländern Europas zielt. Die Gesellschaft operiert von Standorten in Frankfurt, Stockholm und London aus und verwaltet Fonds mit einem Volumen von 1,7 Mrd. Euro. Über den Kaufpreis wurde Stillschweigen vereinbart. Der Verkauf steht unter dem Vorbehalt der Zustimmung durch die zuständigen Kartellbehörden. Energieoptimierung durch effiziente Wärmeübertragung im Glühprozess Das Drahtwerk Elisental W. Erdmann GmbH & Co., Neuenrade, plant die Errichtung einer innovativen Abkühl-/ Aufwärmstation, um seinen Energieeinsatz zu optimieren. Das Unternehmen hat sich auf die Herstellung von Drähten aus Aluminium- und Magnesiumlegierungen spezialisiert. Die Drähte müssen einen Glühprozess durchlaufen, um die beim Ziehprozess entstandene Kaltverfestigung rückgängig zu machen und dadurch die Umformbarkeit wieder herzustellen. Ziel des vom Bundesumweltministerium (BMU) geförderten Vorhabens ist es, die Abwärme der Drahtcoils für die Vorwärmung der kalten Coils vor dem Glühvorgang zu nutzen. Dadurch kann einerseits Heizenergie eingespart und zugleich die Ofenkapazität erhöht werden, da der Abkühlvorgang bisher zumeist in der Ofenkammer stattfand. So soll der Prozess des Abkühlens aus den Kammeröfen ausgelagert und zusammen mit dem Prozess des Vorwärmens in einer neuartigen Anlage vereint werden. Die geplante Aufwärm-/Abkühlsta- tion für zunächst ein Glühofenpaar besteht aus einer Thermokammer, in der ein Ventilator für eine starke Luftumwälzung und damit gleichmäßige Verteilung der Wärme sorgt. Ein vergleichbares Gebläse befindet sich in den Glühöfen, das nun nicht mehr benötigt wird. Durch die geplante Aufwärm-/Abkühlstation kann Energie eingespart werden. Die Temperatur eines geglühten Coils beträgt im Schnitt circa 500 °C, das entspricht bei einem Coilgewicht von zwei Tonnen einem Wärmeinhalt von ca. 860.000 kJ bzw. 239 kWh. Das Unternehmen schätzt, dass mit der Kombistation ein kalter Coil auf eine Temperatur von 150 °C vorgewärmt werden kann. Der Wärmeinhalt wird damit auf rund 233.000 kJ bzw. 64 kWh erhöht. Bei erfolgreicher Umsetzung des Vorhabens will das Unternehmen auch die übrigen fünf Ofenpaare mit diesen Stationen ausstatten. Damit könnten im Werk insgesamt rund 220 Tonnen CO2 pro Jahr eingespart werden. Das BMU fördert das Projekt mit 42.000 Euro. ALUMINIUM · 1-2/2008 NEWS IN BRIEF European Aluminium Award 2008 An opportunity to be in the limelight When the ‘Aluminium 2008’ trade fair opens its gates on 23 September, the international aluminium community will attend an event that has over the years developed to become the number-one meeting place for the industry and its applications. More than 700 exhibitors from 40 countries will present their innovations to 16,000 high-calibre trade visitors from about 100 countries. The trade fair is a good opportunity to take part in the competition for the European Aluminium Award that recognises the highest standards of excellence in innovations for the aluminium industry and honours companies for their outstanding achievement. The Award competition is once again being organised by the Aluminium Centrum (Houten / The Netherlands) in conjunction with the European and the German aluminium associations, EAA and GDA, as well as the organiser of Aluminium 2008, Reed Exhibitions. The competition is a platform for companies to demonstrate their innovative capability and offers winners a boost in marketing and exposure. As one of the 2006 winners, Mr. Cavezzan from Castaldi Illuminazione, said: “Inquiries for the product started to raise higher than ever before.” The aims for the European Aluminium Award 2008 are as follows: • To present aluminium to a broad public as an innovative, modern, sustainable and ecological material • To honour companies that invest money and energy in developing new and outstanding products • To present the aluminium industry as responsible, with an interest in forward-looking development • To highlight the capability of the industry regarding new applications • To add further value to the exhibition visitors and the exhibition’s special programme. Designers, builders, manufacturers as well as importers and constructors may participate in the 2008 Award. The following criteria will be taken into account in the assessment of the entries: • Originality and functionality of the use of the material: the degree to ‘Put up or shut up’ deadline for BHP Billiton The Takeover Panel has imposed a deadline of 6 February 2008, by which BHP Billiton has to either announce a firm intention to make an offer for Rio Tinto plc under Rule 2.5 of the UK Takeover Code or state that it does not intend to make an offer. If BHP refuses a formal bid for Rio it will be bound by Rule 2.8 restrictions for six months from the date of its announcement. Rio Tinto welcomed this ‘put up or shut up’ deadline. The Board unanimously rejected BHP’s three-for-one share offer submitted early in November. “By 6 February, BHP Billiton will have had three months to make a decision. Rio Tinto believes it is in the interests of the Group and its shareholders that this period of uncertainty is brought to an end”, the company announced. Rio Chairman Paul ALUMINIUM · 1-2/2008 Skinner added: “Rio Tinto‘s very strong existing portfolio will create significant future value for shareholders. We have been very clear as to where we stand and feel it is time for BHP to do likewise.” To fend off BHP’s advances Rio announced at the end of November that it will increase its 2007 dividend by 30 percent and raise its divestment target by 50 percent to US$15bn. Furthermore, the prospect of “an exceptional growth strategy in iron ore and a strong pricing outlook, with a conceptual pathway to treble production to over 600 million tonnes per annum” (company report) is another cornerstone to retain independence. Latest news close to editorial deadline: English papers headline that ‘BHP prepares to go hostile in Rio bid battle’ (Sunday Telegraph). which the metal aluminium is used in an original and useful manner • Functionality of the product: the degree to which the part meets both its primary user function and its technological function, as a result of the use of materials, construction and any ergonomical adjustments • Design: the degree to which the design as a whole achieves a harmonic unity or a solution – by the construction of the design and the details of the shape, all this in relation to the material used • Durability: in relation to life cycle costs • Recycling: the possibility of recycling the applied materials and the raw materials used • Representativeness and promotional value for aluminium • The designs must have been taken into production • Products or projects must be entered on one‘s own initiative. Further information about the European Aluminium Award 2008 and details of how to enter are available on www.aluminium-award.com. Corus to sell its smelters in Germany and The Netherlands Corus and Aluminium Industrial Acquisition Company Ltd (AIAC) have signed a non-binding letter of intent for the proposed acquisition of Corus’ aluminium smelters by an affiliate of AIAC for an undisclosed sum. Internal consultation and advice processes related to the transaction have begun. A sale and purchase agreement would only be entered into once these processes are completed. The proposed transaction may be subject to certain external regulatory clearances. The two smelters are based at Delfzijl in the Netherlands and at Voerde in Germany and produce over 200,000 tpy of primary aluminium. The smelters employ 481 people in Germany and 475 people in the Netherlands. paw 9 AKTUELLES Ernüchterung im Fenstermarkt daten massiv ein. Doch auch die vorwiegend energetische Modernisierung und Renovierung von Wohngebäuden konnte sich wider Erwarten dem Abwärtssog nicht entziehen. Diese beiden Negativeffekte konnten auch durch die Nachfragebelebung im Nicht-Wohnbau nicht ausgegli- Foto: www.alufenster.at Der deutsche Fenstermarkt ist 2007 kräftig eingebrochen: Der Absatz sank um 7,8 Prozent; das Marktvolumen beläuft sich nun auf 11,7 Mio. Fenstereinheiten (1 FE = 1,69 m²). Einen derart massiven Nachfrageeinbruch hatte die Branche nach dem fulminanten Wachstum 2006 (+ 9,6%) nicht erwartet. Der Außentürenmarkt ging um 4,5 Prozent auf 1,1 Mio. Einheiten (2006: + 5,4%) zurück. Gemessen am Absatz ist der Umsatz bei Fenster und Türen aufgrund der steigenden Werthaltigkeit etwas weniger drastisch ausgefallen. Soweit die Ergebnisse einer aktuelle Studie, die von Branchenverbänden gemeinsam mit dem Marktforschungsinstitut Heinze erarbeitet wurden. Für 2008 wird sowohl im Fenster- als auch im Außentürenmarkt wieder eine moderate Belebung erwartet. Zum Jahreswechsel gab speziell der Wohnungsbau ein düsteres Bild ab. Wie befürchtet brachen aufgrund des Wegfalls der Eigenheimzulage und der Mehrwertsteuererhöhung Anfang 2007 die Baufertigstellungs- Aluminium-Rahmenmaterial konnte sich 2007 dem Absatzeinbruch bei Fenstern und Türen entziehen chen werden, so dass 2007 der Fenstermarkt in den Sog der negativen Bauinvestitionsentwicklung geriet. „Diese Marktentwicklung ist umso unerwarteter, als die in der breiten Öffentlichkeit geführte Diskussion über Energieeinsparung und Klimaschutz sowie die exorbitant steigenden Energie- und Strompreise eine deutliche Nachfragebelebung nach energieeffizienten Fenstern hätten erwarten lassen“, kommentierte Ulrich Tschorn, Geschäftsführer des Verbandes der Fenster- und Fassadenhersteller in Frankfurt die Marktlage. Der erfreuliche Anstieg im Industriebau, bei Büroimmobilien, Lagergebäuden und Hotels brachte eine Verschiebung der Rahmenmaterialanteile zugunsten von Aluminium (+5,0%). Für 2008 erwartet die Branche ein bescheidenes Wachstum von 1,1 Prozent auf 11,8 Mio. Fenstereinheiten. Für den Außentürenmarkt wird ein kleiner Zuwachs von 0,4 Prozent prognostiziert. Die Zuversicht auf eine leichte Belebung des Marktes stützt sich auf die steigende Nachfrage im Bereich der energetischen Gebäudemodernisierung im privaten und vor allem im öffentlichen Immobilienbestand. Deutschland 2007 Sinkender Energieverbrauch trotz Wirtschaftswachstum Der Energieverbrauch ist 2007 in Deutschland mit 13.842 Petajoule auf das niedrigste Niveau seit der Wiedervereinigung abgesunken. Gegenüber 10 2006 beträgt der Rückgang 5,0 Prozent, gegenüber 1990 7,1 Prozent, so die aktuellen Zahlen der Arbeitsgemeinschaft Energiebilanzen. Bei einem Anstieg der Wirtschaftsleistung um 2,4 Prozent gegenüber dem Vorjahr hat sich der spezifische Primärenergieverbrauch 2007 unbereinigt (ohne Witterungseffekte) um 7,5 Prozent und bereinigt um rund sechs Prozent verbessert. Der spezifische Energieverbrauch (unbereinigt) hat sich seit 1990 damit um rund zwei Prozent pro Jahr verringert. Mit dem rückläufigen Energieverbrauch sind auch die energiebedingten CO2-Emissionen deutlich gesunken. Nach ersten Abschätzungen des Bundesministeriums für Wirtschaft sind sie 2007 gegenüber dem Vorjahr um 3,6 Prozent gesunken; gegenüber 1990 beträgt der Rückgang 19,3 Prozent. Damit ist Deutschland auf gutem Weg, seine Kyoto-Verpflichtung (Reduktion um 21 Prozent bis 2012) zu erfüllen. ALUMINIUM · 1-2/2008 NEWS IN BRIEF Aluminium India 2008 makes impressive strides Aluminium India 2008, the International Conference and Exhibition will be held in Mumbai from 22 to 24 February in order to address the needs of the Indian aluminium industry in the context of global markets and new technologies. The trade show has confirmed participation of about 70 exhibitors, which will display the latest technology, trends and applications from across the world. A formidable international participation already pegged at 60 percent leaves nothing to imagine. Trade visitors to the show can very well expect a world of aluminium on and can benefit in an atmosphere charged with productivity. The show has the support of the Ministries of Mines, Science and Technology as well as the leading associations like Federation of Mineral and Metal Industries, Cable and Conductors Manufacturer Association promises to be the most comprehensive platform on aluminium in India. A host of visitor viz CEO’s, directors, ALUMINIUM · 1-2/2008 plant and process managers, entrepreneurs, consultants, senior bureaucrats, students amongst others are expected to visit and witness the future unfold. The silver lining is the high profile inauguration of the show by the Minister of Mines accompanied by the Secretary, Mines and other senior government officials from various states. The cutting edge international conference Alcastek will see a large number of foreign participants and presentations on best practices across the world. Mr. G. Kirchner, Chairman of the Global Aluminium Recycling Committee from Germany, will speak on the ‘Current and Future Perspectives of Global Recycling of Aluminium’. Director of Vedanta Resources, Mr. S. K. Timotia will speak on the related issue of ‘Current Energy and Environmental Issues in Aluminium Industry ‘. Aluminium India 2008 will host the technical session which is being divided in various segments to meet the demands of the industry. The plenary session is going to discuss the global trends by the leaders of the aluminium industry. Mr. P. Suri, President, Balco, India will be addressing the plenary session ‘an overview of the industry’; he has been associated with the industry almost all his life. The metal has varied uses in almost every industry, from aircrafts to automobiles, from power cables to foils. One reason is that aluminium can be fashioned into countless shapes in a variety of applications because of its basic malleable qualities. Aluminium is gaining ground in the transportation industry because of its light weight which translates into higher payloads and lower fuel consumption. Indian railways is increasing its consumption of aluminium in railway wagons. The aerospace industry is another large consumer of aluminium. The automotive sector has also increased use of the metal in various body and engine parts. 11 WIRTSCHAFT 12 ALUMINIUM · 1-2/2008 WIRTSCHAFT Produktionsdaten der deutschen Aluminiumindustrie Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte** Produktion (in 1.000 t) +/in % * Produktion (in 1.000 t) +/in % * Produktion (in 1.000 t) +/in % * Produktion (in 1.000 t) +/in % * Nov 41,9 -17,9 73,0 11,8 163,9 8,7 52,1 10,2 Dez 42,8 -10,1 61,6 12,9 124,1 1,2 34,6 10,2 Jan 07 40,9 -4,5 70,7 8,1 147,8 -2,7 51,1 12,6 Feb 37,1 -4,1 71,1 9,2 154,7 -2,5 49,9 8,3 Mrz 41,5 -3,8 75,2 -4,7 177,1 -0,6 54,7 5,3 Apr 41,8 -1,4 67,0 7,1 158,1 6,0 47,3 10,5 Mai 46,4 7,0 71,4 5,0 166,5 -2,5 50,8 2,2 Jun 46,5 7,8 73,6 12,0 164,8 0,7 51,7 8,1 Jul 48,7 8,1 72,5 13,2 167,1 1,5 53,3 9,8 Aug 49,0 8,5 63,5 6,7 164,8 -1,1 51,5 7,2 Sep 47,0 9,8 69,7 4,1 156,7 -2,3 50,2 -1,8 Okt 50,2 13,8 74,1 14,1 170,7 0,4 55,4 6,0 Nov 49,7 18,5 73,0 0,0 155,8 -4,9 53,7 3,1 * gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf Primäraluminium Walzprodukte > 0,2 mm 14 Sekundäraluminium Press- und Ziehprodukte ALUMINIUM · 1-2/2008 ECONOMICS A normative analysis exploring alternative business models Which globalisation for the aluminium industry? – Part I B. G. Rüttimann, Singen Hardly a day passes without news or rumours about friendly or hostile takeovers or mergers in the aluminium and other industries. In the attempt to maximizing profits under the umbrella of increased competition and limited growth in advanced countries on the one hand, but with a view to sustained growth in emerging economic areas on the other hand, a new era of company gigantism has made its appearance. To secure access to raw material sources for the supply of the fast-growing new economies, combined with their highly competitive labour cost structure, the BRIC (Brazil, Russia, India, China) countries together with the leading 16 Western technologically advanced companies will establish a new economic world order. In the aluminium industry, the merger of Alcan with Alusuisse and Pechiney gave the initial impetus for the creation of a new industrial logic. The AlcoaKaiser merger followed. Similar aims, but with a different focus, were the intention behind the Hoogovens and Fig. 1: The Business Typology Matrix [4] British Steel merger patterns regarding this phenomenon. which formed the Corus company. Moreover, the word globalisation still Norsk Hydro has grown with the makes many employees feel uneasy, VAW take-over and, in a second step, since they fear becoming victims of concentrated on aluminium activicompany mergers and loosing their ties. Alcoa Extrusion and Sapa have jobs. In what follows, we will discovformed the largest extrusion coner that globalisation is not always the glomerate and Mittal took over Alsame thing and that strategies have to can’s Novelis spin-off. And now, after follow different schemes correspondthe Rusal, Sual and Glencore merger ing to the intrinsic nature of each busiforming Russian UC Rusal aluminium ness. This paper aims to outline some giant, we have seen the Rio Tinto minstructured thinking that will help to ing giant successfully bidding for the understand the future industrial logic aluminium giant Alcan [1,2]. Out of of the changing aluminium industry. the originally 12 integrated big aluminium concerns that existed in the 1980s, today it seems that not one of Characteristics of the Western concerns will survive the aluminium business [3]. The names and configurations of To gain insight into the globalisacompanies are changing continuously tion phenomenon, we have at first to with the intention to form an ideal understand the intrinsic nature of a business constellation which will business. A business system is mainly gain competitive advantages within composed of: the global market challenge, consist• the transaction object, i. e. the ent with the doctrine of maximizing product or service profits in each case. In this context • the supply and demand structure, the word ‘globalisation’ is used all with the related transaction the time and often applied as a catchscheme, and word indifferently, without having • the operating configuration of perceived the subtle differences of supply. Illustrations: Rüttimann The aluminium industry is at present undergoing a fundamental transformation. After the concentration of vertically integrated aluminium concerns we are now experiencing on the one hand the formation of big aluminium mining groups and on the other hand the creation of process-technology specialised groups for the semifinished product sector. All this has to be seen under a rationale that aims to control raw material sources and to respond to increased competition in search of maximizing profits. Which are the economic models governing the ongoing logic of globalisation? What will the present aluminium industry system look like in the future? Are the fully integrated aluminium groups a run-out model? Do small and medium-sized companies still have a chance to survive? The following contribution analyses the different competitive systems within the valueaddition chain of the aluminium industry in order to explore the rationale of alternative business models within the present globalisation phenomenon. ALUMINIUM · 1-2/2008 ECONOMICS The backward determinants themselves which influence product characteristics, market structure, and determine the business classification, and finally the operating configuration, are: • value of the product • transport costs and related range of distribution • production factors in terms of cost drivers • demand profile and • supply structure. These main determinants characterise each business type within an industrial system. Certain combinations of these determinants reveal clear patterns for each business type. The representation of product-characteristics (differentiated or not) on one axis and market-structure (oligopolistic or fragmented) on another axis within a matrix, leads finally to the following landscape of basic business types [4]: • commodities • specialties • standards • convenience. Fig. 1 presents a clear, systematic and structured view with which to classify businesses roughly into types. It goes without saying that mixed types may exist. The ‘commodity’ type of business (e. g. metal ore or wheat) comprises all kind of goods listed in efficient marketplaces such as commodity exchanges, where world market prices apply. The ‘specialty’ type of business (e. g. electronics or automobiles) embraces those durables and consumables goods with a distinctive brand, and are thus governed by an imperfect competition. The ‘standards’ type of business (e. g. cement or extrusions) covers intermediate or semi-finished products with a rather polypolistic supply structure. The ‘convenience’ type of business (e. g. clothing, but also hotels) embraces most of the products we come across sold in retail stores in a very fragmented market to reach the end user, and from the supply side represents an imperfect or monopolistic competition. Let us now try to fit the aluminium technologies into this matrix. Bauxite mining is an ore extracting operation often performed by big vertically in- ALUMINIUM · 1-2/2008 Indeed, the customer asks primarily tegrated aluminium companies or three questions: “Can you manufacmultinational mining groups, and is ture this product? When can you supcharacterised by a clear oligopolistic ply it? How much will it cost?”, so exmarket structure. By definition the trusion companies do not supply just differentiation aspect of a commodity a product, but also perform a service does not exist, except perhaps in relaby putting their production capacities tion to ore content. The same applies to the service of their customers and to calcined alumina. The outcome of trying to achieve the shortest delivery the smelting process is primary alutime, accurate punctuality and speciminium, traded as ingots on commodfication-conforming quality [5]. In the ity exchanges mainly as the 99,7% aluminium industry we can sometimes grade. For primary aluminium too we also observe downstream integration have the same oligopolistic structure in the value-addition chain, such as composed of MNEs (Multi-National ready-to-fit components or systems Enterprises) with some independent for the building industry. These prodSMEs (Small Medium Enterprises) as ucts have already a quite advanced exceptions. We can classify all these differentiation degree regarding the goods as belonging to the commodity solution proposed. On the other hand type of business, goods flowing from the degree of concentration from the their natural origin to the big conversupply point of view may vary. Neversion centres. The world of semi-fabtheless, we can classify such sectors as ricated products is mainly composed belonging in-between the specialties of the technologies rolling, extrusion, type of business. castings, forgings, and thin-foil rolling. Although often these plants belong to MNEs, the operating configuration has a more fragmented structure imposed by the desire for proximity to the customers; MNEs try to serve a wider geographical area by setting up a network of plants. The reasons for fragmentation originate from the cumbersome shape of the products but also the need to interact with custom- Fig. 2: Aluminium technologies within the Business Typology Matrix ers, so resulting in a more regionally orientated business. From Fig. 2 we can see that the prodThe fragmentation of the business ucts (or technologies) of the aluminfavours the concomitance of SMEs ium industry rather belong to the mainly in the sectors of extrusion, commodities and standards type of casting and forging. For example, in business; this seems to be reasonable the case of extrusion SMEs make up due to the fact that the transaction 50% of the plants [3]. type is rather a B2B than a B2C. All these technologies can be classified as belonging to the standards The different perceivable type of business. These are intermepatterns of globalisation diate goods with a low degree of product differentiation. We can even clasGlobalisation is not always one and sify the transaction object rather as a the same thing [4]. This is also observice than just a physical product. servable in the aluminium in- © 17 ECONOMICS Fig. 3: The Globalisation Type Matrix [4] dustry. In fact, once having classified the businesses, the question is how globalisation is influenced by each business type, or rather how globalisation of the business evolves in each business type and according to which pattern. Analysing the business types, it emerges that the operating configuration determined by the business is a major determinant for the globalisation type. The intrinsic logic reveals two main types [4]: • type 1: material (or physical) globalisation for commodities and specialties • type 2: immaterial (or financial) globalisation for the standards and convenience. The difference is substantial. Products of businesses following type 1 globalisation could ultimately be produced within a single plant operating configuration and shipped physically worldwide, whereas products of businesses following a type 2 globalisation are produced locally for the local market. MNEs will have in this case a network of local companies by FDI (Foreign Direct Investments) and the business idea is to exploit the specific know-how in doing business. In this fragmented market they have to buy 18 or set up new enterprises to increase market share. But for type 1 globalisation we have to distinguish between commodities and specialties. Let us call type 1a the ‘globalisation of commodities’; through the listing on efficient market places like commodity exchanges, this represents the pure example of a globalisation of business. Nobody can escape from this type of globalisation because its effects are spreading all over the world. For type 1b ‘globalisation of specialties’ the product characteristics are unique and therefore – to some extent – the price can be fixed by the supplier taking into account the value for the customer. This is due to the possibility of product differentiation within the competitive system. For type 2 globalisation this distinction between subtypes is not necessary. Indeed, according to Chamberlain markets not involving material (physical) flows of products over a certain distance represent a local monopoly. So there is no need to differentiate globalisation patterns between standard and convenience product types. Are there any drivers able to upset this apparently stable situation? Yes, there is one. If the difference in price for the same goods in different economies exceeds a certain threshold, exports can temporarily become possible also for products following type 2 globalisation. We may call this ‘economic arbitrage’. In these cases we can also observe a material flow of products within the type 2 globalisation characterised businesses; let us call this type 1c globalisation ‘opportunistic or low-cost globalisation’. Typical are the exports of low-cost countries such as China to the advanced economies. But if a price difference also exists in different economies for the salaries of white-collar jobs – and the skills are equivalent – then it is also possible that enterprise functions such as R&D, call centres or accounting are outsourced to low-cost countries like India; let us call this type 3 globalisation the ‘globalisation of human factor or service’. Fig. 3 shows all the types of globalisation within a matrix which allows a rough identification of the type of globalisation and, from that, the possible evolution or competitive issues to face within a certain business. It Fig. 4: Type 1a or globalisation of commodities ALUMINIUM · 1-2/2008 ECONOMICS goes without saying that mixed types may exist. Moreover, these different globalisation types also follow different economic laws. Type 1a is characterised by global price building at commodity exchanges and mainly unidirectional material flows from countries of origin to the countries of transformation (Fig. 4). The preference for a raw material such as aluminium compared to another such as steel depends on the ‘latent value’ of a specific resource compared to the substitute resource [4]. This also takes into consideration the ecological impact or the end-ofcycle aspects. Globalisation type 1b is characterised by bi-directional flows of the same products between different economies (Fig. 5). The preference for one product compared to another depends on the ‘cost-benefit’ perception of the customer which can be translated into the ‘competitiveness factor’ for differentiated products of a producer [4]. This goes far beyond the Ricardian comparative cost advantage for heterogeneous but non-differentiated products. The higher the competitiveness factor, the higher is the market share of the producer. This can be seen as the modern interpretation of the Heckscher-Ohlin factors proportion theory. The type 2 globalisation products depend on the ‘intrinsic market fragmentation’ of the business [4]. This market fragmentation is given by the characteristic of the product and the logistics and cost for it to be transported (Fig. 6). Indeed, combined with the fragmentation of the final demand, this is an indicator for the necessary Fig. 5: Type 1b or globalisation of specialties ALUMINIUM · 1-2/2008 polypolistic offer structure to reach the next transformation stage of the value-addition chain or to be distributed to the final customer. The types 1a, 1b, and 2 are the natural globalisation types. Type 1c is based on the price differential of the same product between two economies, which we may call the ‘propensity for globalisation’ [4]. The higher this difference is, the higher are the material flows of such products although – from the intrinsic nature of the business – this should result in type 2 globalisation as is typically the case for extrusions (Fig. 7). This globalisation lasts as long as the price difference exists, i. e. as long as the incentive is high enough. In particular, extrusions in North America are being confronted with the type 1c globalisation phenomenon from China [6]. Type 3 globalisation is modelled by the ‘comparative skill of labour’, i. e. the level of skills available and the respective cost as well as the cost of transferring the service considered to a lower-cost economy (Fig. 8). This globalisation type too will last as long as the salary cost advantage persists. The intrinsic logic and mathematical models governing the triggering and evolution of each globalisation type are beyond the scope of this limited discussion and can be consulted in the appropriate literature [4]. Applying these findings to the portfolio of different aluminium technologies shown in the matrix of Fig. 2 we can assert the following: the bauxite, alumina, and primary aluminium businesses follow rather a material type 1a globalisation pattern, i. e. the growing demand in emerging coun- tries will boost the flow of raw materials from the sources to these new industrializing regions. The material flows will grow not only in volume terms; the interaction of the different economies will also increase and the centre of gravity will shift to these new emerging economic regions. Rolling, extrusions, castings, and forgings will rather follow a financial type 2 globalisation pattern, with companies building up a network of similar operations via FDI in accordance with a market coverage strategy. Indeed, Sapa and Hydro, but also Indalex limited to the North American region, are typical examples of extrusion industries that follow such a market coverage strategy, exploiting their know-how of manufacturing and to promote their extrusion business. The spin-off regarding the ex-Alcan rolling activities forming Novelis, as well as Aleris from Corus, are also good examples of how to create a technology-centred business model focussed on the better servicing of market needs. Despite the fact that the casting and forging industries used to be dominated by familyowned, single plant companies, there too a tentative creation of networks can be observed. All these polypolistic businesses are characterized by an increased level of M&A or the set-up of new plants in emerging economic regions. On the other hand, type 2 strategies can also be observed in type 1a characterized markets, such as the merger of Rusal, Sual, and Glencore. But here there exists a big difference in the logic: whereas on the one hand in markets primarily characterized by type 2 globalisation the business itself is fragmented and remains regional, on the other hand when a secondary type 2 pattern overlies a type 1a pattern, the markets remain characterized by material flow from the countries of origin to the destination countries all over the world. In fact, the first case is a ‘conditio sine qua non’ for growth in new geographic regions, while the second case provides the option to growth further when the present mines are reaching their exploitation limits. The ongoing concentration process of the aluminium primary industry is a typical example [3]. Building applications such © 19 ECONOMICS Fig. 6: Type 2 or financial globalisation as window and façade systems can be considered to belong to the type 1b globalisation pattern. Indeed, despite the rather fragmented building industry, proprietary building systems from suppliers such as Schuco and similar ones are often sold worldwide as the consequence of winning international contracts. Further, in our industry we also have examples of globalisation type 1c. In fact, for some years exports of extrusions from China to the United States have been increasing rapidly and attained a market share of an astonishing 9% at the end of 2007 [6]. The price differences between imported and locally produced extrusions observed were up to 20%, showing a high propensity for globalisation which made it possible to ship standardized products even across long distances. Despite that, due to its fragmented characteristics the extrusion market follows naturally, if ever, a type 2 strategy. This transient type 1c globalisation will last as long as the price difference is large enough [4]. Generally, all these imperialistic expansion strategies are often denounced by public opinion. But the natural types of globalisation (i. e. 1a, 1b, 2) are not responsible for social consequences such as unemployment; the socio-political consequences are mainly caused by the transient types of globalisation (i. e. 1c and 3). That, however, is another story. The phenomenological modelling of economic globalisation presented here is further accompanied by a common denominator for the intrinsic reason of macroeconomic globalisation evolution. This rationale behind it, which 20 is grounded on entropy-based inequality and derived risk metric, leads to The Central Theorem of Globalisation an explanation of which would be far beyond the scope of the present paper [4]. The peculiarity of the aluminium industry’s value-addition chain The aluminium industry has been mainly composed of fully vertically integrated concerns covering bauxite extraction, alumina refining, primary aluminium smelting, various semis production technologies, and sometimes going as far as the manufacture of fully-finished components for the automotive, aerospace or electrotechnical industries (Fig. 9). It is interesting to see the apparently neat division between the upstream operations (bauxite, alumina and primary) and the so-called downstream technologies (rolling, extrusion, casting, and forging). Indeed, primary aluminium production is a two-step cascaded process supplying the common basic raw material to all the other aluminium semis operations. The figure also shows the relative business typology and related globalisation type at each level of the value-addition chain. Accordingly, we cannot simply say that a general globalisation tendency can be observed in the aluminium industry; it can also be asserted that it will perform differently along the addedvalue chain in accordance with the different logics, with different effects on the competitive system as well as the social system of employment. Moreover, there are evident differences between the levels of the value-addition chain. Although the semis operations have the same globalisation type, we can assume that between the different semis operations there are no relevant synergies observable from a management point of view (except in contingent situations), and of course the alloys used are often quiet different, with separate recycling loops, and the products from different technologies are only partly, if ever, substitutable and therefore need different conceptual engineering design. The reason for backward integration is more related to having direct access to the aluminium metal, i.e. to securing the supply side. So are fully integrated aluminium concerns a run-out model? This depends largely on the business model adopted by the parent company and will be a key issue in examining the survival logic of today’s remaining aluminium companies. In general it can be said that it is difficult to dominate a business profitably beyond a certain well-defined range of the whole value-addition chain. There are mar- Fig. 7: Type 1c or opportunistic cost globalisation ALUMINIUM · 1-2/2008 ECONOMICS keting, technological and management reasons for this, going back to the concept of economies of scale. Indeed, there is no integrated company that fabricates a final product such as a car, which is fully backward integrated. Specifically, taking the example of the automotive industry, companies concentrate on core activities such as engine development (and manufacturing) and especially the whole assembly operation of the car. This represents a very tiny range of the value-addition chain of automotive manufacturing. Indeed, today the added value generated per hour is more important than the added value generated per car, For brand marketing reasons it is important to be able to sell more cars with the same brand and increased prestige, as well as to increase the buying power for the components [7]. An alternative to vertical integration could be to have a horizontal expansion of the same technology, such as rolling for Novelis and extrusions for Sapa, or at least similar ones that offer synergies from the technological point of view or for the same markets with different technologies in order to offer alternative solutions, such as Corus with steel and aluminium (which is no longer being pursued due to final concentration on the steel business). This can take place at every level of the value-addition chain, i. e. mining, or smelting, or rolling, or extrusion, or even casting (sand or diecasting, steel and aluminium). In general the following basic question has to be answered: is the core business content to sell products of a specific technology to all markets, or is the core business content to serve a specific market with different technologies? The first model has more a capacity-filling logic and the second one more a product-solution approach. This distinction is more important than many people believe; there is nothing worse than believing that one is selling a product for a certain application market whereas in reality the destination of the application market is irrelevant and the transaction object is rather a service with the underlying business following a technological capacity-filling logic irrelevant to the application. In fact, care must be taken not to follow the often undifferentiated preaching of “you have to become market-orientated” by generic consultants of the past, which was often understood as application segmentation. It is necessary to understand the intrinsic logic of each single business, to achieve not only undifferentiated customer orientation but even very differentiated customer dedication that fulfils their specific needs even inde- © INDUSTRIAL DESIGN & ENGINEERING IS YOUR INNOVATION THE WINNER IN 2008? ENTER NOW! WWW.ALUMINIUM-AWARD.EU ORGANISING PARTNERS MAIN SPONSORS MEDIA SPONSORS WWW.ALUMINIUM-AWARD.EU Fig. 8: Type 3 or globalisation of human factor ALUMINIUM · 1-2/2008 21 ECONOMICS production increases the nonsold ingot stock and the LME ingot price will go down because supply exceeds demand. On the other hand, the bauxite and alumina production level, which can be controlled to some extent, Fig. 9: The value-addition chain of the aluminium industry can be adapted to demand. The bottleneck will most pendently of the application [5]. The probably be formed by the railway’s semis industry is characterised by B2B capacity to transport the bauxite. and not B2C marketing. UnderstandFrom that point of view it makes sense ing the intrinsic nature of the semis to combine bauxite and alumina probusiness will be the key to success in duction (including reflections about future competition. Of course, certain optimised sourcing of caustic soda) technologies are more appropriate for in order to reduce the transportation MNEs than for SMEs due to capital volume by half. It becomes evident intensiveness. But everyone has the that primary aluminium production possibility to participate in the race is a different business from mining for global dominance. It is evident although it belongs to the same glothat the possibility to build-up a type balisation type. For that reason we can 2 globalisation strategy for a specific assert that for the mining giant Rio semis technology is very realistic, as Tinto to go into the primary aluminthe logic and examples show. ium business is already a downstream These are the known facts – so expansion into a new technology. what next? Taking into consideration Another interface exists between these few thoughts, we can question components manufacturing and the the logical division marking the indifferent semis-operations. To interface between upstream and downcrease the supplied value-addition stream with the transfer product becontent of semis-products, semising the ingot (or rolling slab as well as plants try to perform additional meextrusion billet). The risk of remainchanical operations as a service to ing short of metal supply is marginal their customers or even become infor SMEs that carry out downstream volved in component development operations, considering their produc[7]. The question is how far this tion capacities in relation to the total should go. If the downstream activity metal supply. For MNEs, long-term comprises more than only finishing contracts with primary producers can operations but rather the fabrication bypass the issue of not having one’s of ready-to-fit parts (even combined own metal production. This is valid with engineering content), the busifor all operations where pricing is ness content might be quite different generally based on tolling or similar from pure semis production, with a margin calculations. Are there other production philosophy of one-piece interfaces? Yes, as also between aluflow in one case and batch producmina and primary metal. Indeed, the tion in the other case. The decision peculiarity of the electrolysis process to go along that road has to be well that yields liquid primary aluminium evaluated. is that it necessitates a continuous, It becomes evident, that not only uninterrupted process. The cells have the globalisation pattern may be difto be constantly fed with alumina (and ferent for each step of the value-addicurrent) in order to avoid sealing. The tion chain, but also that the intrinsic liquid metal output of a smelter is conissues are specific to each step. In the stant and in case of low demand, the 22 next section we will see that also the CSFs (Critical Success Factors) are specific to each step of the value-addition chain. To be continued in ALUMINIUM 3/2008 References 1) Rio Tinto to buy Alcan, ALUMINIUM 7-8/2007, Giesel Verlag. 2) Pawlek R., The Rio Tinto Alcan deal – marking the dawn of a new era for metals, ALUMINIUM 9/2007, Giesel Verlag. 3) Conserva, M.: Global Market Trends of Aluminium and Aluminium Products, Proceedings of the 6th World Congress ALUMINIUM 2000, Florence Italy, March 13-17, 2007, Interall publications. 4) Rüttimann, B.: Modelling Economic Globalisation – A Post-Neoclassic View on Foreign Trade and Competition, Verlagshaus Monsenstein und Vannerdat, Edition MV-Wissenschaft, Münster, 2007; ISBN 978-3-86582-447-9. 5) Rüttimann, B.: Strategy and tactics in the aluminium semi-finished products industry, ALUMINIUM 78 (2002) 1/2 and 4. 6) Rüttimann, B.: The Globalisation Trap of the Aluminum Extrusion Industry, Paper to be presented at the 9th International Extrusion Technology Congress ET08, May 13-16, 2008 Orlando FL USA. 7) Hagen, H.; Rüttimann, B.: The automotive market – the new challenge for the aluminium industry, ALUMINIUM 80 (2004) 3 and 4. Author Dr.-Ing. Bruno G. Rüttimann, MBA, graduated from Milan Polytechnic and Bocconi University of Economics in Milan. Since 2003 he has been in charge of continuous improvement within Alcan Engineered Products. As Master Black Belt he supports the introduction of the Lean Six Sigma culture to increase the competitiveness of the plants. ()##!)#$* ! &#$# !"!#$ % '''%!#$ % ALUMINIUM · 1-2/2008 ECONOMICS Marubeni predicts aluminium surplus in 2008 Japanese trading house Marubeni expects a global aluminium surplus of 543,000 tonnes in 2008 as new production comes on stream, but predicted a tightening in 2009 on increased Chinese consumption. Global aluminium consumption will grow by 9.5% to 41.26m t in 2008 and a further 5.6% to 43.56m t in 2009. Production in 2008 is expected to grow 10% to 41.80m t as new capacity comes on stream. The surplus of supply over demand in the CIS region may rise from 3.47m t in 2007 to 3.86m t in 2008 as output rises by 10.6% to 5.01m t. The supply-anddemand balance in China, however, is forecast to be perfectly matched in 2008 at around 15m t. However, an 8% increase in Chinese consumption to 16.2m t in 2009 is likely to lead to a 100,000 t shortfall in supply. Global consumption in 2009 is forecast to reach 43.56m t, and production 43.77m t, leading to a global oversupply of around 210,000 t. The trading house is also forecasting prices to continue their upward trend, averaging between US$2,300 and US$3,000 per tonne in 2008, and between US$2,500 and US$3,500 per tonne in 2009. paw Rio’s outlook for metals and minerals For aluminium Rio makes the following forecast: Aluminium consumption has grown the fastest of all non-ferrous metals over the last five years and is forecast to grow rapidly over the next 20 years: There has been enormous recent growth in Chinese consumption and production, but aluminium has benefited from increasing use in many other regions including the OECD. Constraints on China’s domestic bauxite production suggest that the country’s massive investment in primary aluminium will still relay largely on imported bauxite. This, combined with China’s high power costs, means ALUMINIUM · 1-2/2008 that Chinese aluminium capacity will continue to be high-cost in a global comparison. Additionally, Chinese production will eventually suffer from a stronger currency as the RMB edges toward fair exchange rate. The implied increase in the marginal cost of production for alumina and aluminium mean, that their prices are unlikely to revert to the lower levels implied by historical trends. Spot aluminium prices have moderated by about 10% since the middle of 2007 and are currently moving in the range of US$2450-2550 per tonne, which still covers production costs at the highest cost smelters. Forward prices have increased in relation to spot prices reflecting a market expec- tation that smelters with high marginal costs will still be needed to meet demand over the medium term. Aluminium is forecast to continue to enjoy rapid growth over the next two decades. CRU projects consumption to grow by more than 140% over the period to 2030. One reason for the recent growth is that China’s economic development is highly aluminium intensive. But at the same time aluminium has gained worldwide in intensity of use and has partly replaced other materials across a wide range of applications. The strong and sustained growth in aluminium demand is starting to stretch the resource base that has so far allowed unlimited growth of © 23 ECONOMICS the aluminium industry: large-scale, good-quality bauxite deposits and regions of relatively cheap energy. In the case of bauxite the escalation in demand for aluminium is being met increasingly from high-cost and small-scale bauxite deposits in China, and by opportunistic mining operations in Indonesia. Such sources of supply are unlikely to provide a long-term solution for the industry’s rapidly growing bauxite needs and have already led to stronger prices for traded ore. Bauxite supply therefore requires significant investment in large scale mines if the industry is to meet demand projections. Meanwhile, high energy prices, combined with a greater integration between regional energy markets through the development of LNG and gas-to-liquids projects, could increase the costs of power available to greenfield smelters around the world. Together with a likely trend towards the introduction of pricing mechanisms or tax regimes for carbon emissions, sustainable isolated hydropower sources have become more valuable. This in turn may increase the value of existing aluminium capacity linked to such power sources. In the context of growing demand and constraining supply, the longterm price development for aluminium will much depend on the evolution of costs. Turning first to alumina, refineries relying on imported bauxite supplies, such as those in Europe and the US Gulf coast, have traditionally occupied the top-end of the alumina cost curve. High energy prices and rising delivered bauxite costs have aggravated the competitive disadvantage of these refineries during the past five years. The Chinese industry is currently drawing on its capital cost advantage to add significant non-integrated alumina capacity, but these refineries are rapidly joining US and European alumina refineries toward the top of the cost curve. The resulting increase in the marginal cost of production means that alumina prices are unlikely to revert to the lower levels implied by historical trends, even if some higher cost integrated capacity is eventually replaced by lower cost production. In the case of aluminium, as with alumina, new Chinese smelters are fundamentally changing the shape of the industry cost curve. The rapid increase in Chinese smelting capacity since the start of this decade reflects the relatively low entry barriers in building smelters, due to China’s low capital costs and short build times. However, this new capacity has come in at the top-end of the operating cost curve, mainly reflecting relatively high power costs. Consequently, the industry aluminium cost curve has shifted up since 2003 and become steeper. This has provided a new significantly higher base for prices. A key point to note is that the gradual appreciation of the Chinese currency should also translate into higher US dollar production costs for Chinese smelters – all other things being equal. With Chinese smelters predominantly in the third and fourth quartiles, the top end of the curve would shift up in such a scenario creating an even higher basis for aluminium prices and higher margins for smelters elsewhere in the lower cost quartiles. R. P. Pawlek, Sierre China sets guidelines for domestic aluminium and alumina projects In December 2007 China has announced guidelines for those who wish to enter the domestic aluminium industry, according to the National development and Reform Commission. All new development projects in the aluminium sector, including mining, alumina refining, ingot melting and recycling as well as fabrication plants, must abide by all requirements of the various state departments. These include basic requirements for proper land use, safety and environmental regulations. Under the guidelines, smelting facilities cannot be built within one kilometre of protected regions, such as water preservation areas, protected farming areas, protected natural reservations, famous scenic attractions, 24 major cities and their nearby surrounding countryside, as well as hospitals, food, medical and electronic business. New bauxite mining projects with an investment of more than Yuan 500m (US$67.3m) will require approval from the investment management division of China’s State Council. Those with a smaller investment will require approval from the investment management divisions of their respective provincial governments. All mining projects seeking approval must have at least a 300,000 tpy capacity and a minimum life span of 15 years. All new alumina projects must be approved by the investment management division of the State Council. Those using domestic bauxite as feed must have an initial capacity of at least 800,000 tpy, and a minimum lifespan of 30 years; those using imported bauxite as feed must have an initial capacity of at least 600,000 tpy, and reliable feed supply such as longterm contracts for at least five years of delivery. New ingot smelting projects will also require approval from the State Council’s investment management division. In the near term the Council will consider only upgrading projects to suit environmental requirements and to replace outdated machinery. These projects also require guaranteed alumina feed supply, sufficient power supply, and efficient transport conditions. New secondary and recycling aluminium projects must have at least a capacity of 50,000 tpy; existing plants should have at last a capacity of 20,000 tpy, and expansion projects must have ALUMINIUM · 1-2/2008 ECONOMICS – sheet/strip must have at least 50,000 tpy, foil a minimum of 30,000 tpy and extrusion of aluminium 50,000 tpy. R. P. Pawlek, Sierre at least a capacity of 30,000 tpy. In the aluminium fabricating sector, new projects have to focus on sheet, strip, foil and extrusion. Projects with combined capacity must produce at least 100,000 tpy. Approval for projects producing a single product will depend on the product type ECCA ECCA Production of stripcoated aluminium gains new momentum Produktion von beschichtetem Aluminiumband legt erneut zu At its 41st Autumn Conference held between 18 and 20 November 2007 in Brussels the European Coil Coating Association (ECCA) reported sustained growth in the production of strip-coated aluminium. Auf ihrer 41. Herbstkonferenz vom 18. bis 20. November 2007 in Brüssel berichtete die European Coil Coating Association (ECCA) über ein anhaltendes Produktionswachstums von bandbeschichtetem Aluminium. Photos: Alcan Singen Whereas the annual growth rates of Während die jährlichen Zuwachsrastrip-coated steel have averaged ten ten von bandbeschichtetem Stahl seit percent over a number of years, since vielen Jahren durchschnittlich zehn 2000 aluminium had been showing Prozent betragen, war bei Aluminium a downward tendency which was seit 2000 eine rückläufige Tendenz zu not reversed until 2006, with a rise verzeichnen, die sich erst 2006 mit of eight percent compared with the einer Steigerung von acht Prozent year before. Happily, the strip coater gegenüber dem Vorjahr umkehrte. members of the ECCA were able to Erfreulich, dass die in der ECCA announce a new production increase zusammengeschlossenen Bandbefor aluminium strip in the first half of schichter für das erste Halbjahr 2007 2007, by as much as 22 percent comeinen erneuten Produktionsanstieg pared with the same period a year bei Aluminium melden konnten, earlier. That growth can mainly be atund zwar um 22 Prozent gegenütributed to extensive deliveries for the building sector, in which strip-coated aluminium is used for example to produce wall, deck and roof sections and for composite panels, doors and gates. The conference motto was “European regulations: threat or opportunities for coil coating?” In that connection many lectures dealt with the consequences of current European legislation for both strip coaters and the users of strip-coated products. One theme was the influence of European legislation on the building sector, which is by far the largest individual market for coated strip of Bandbeschichtete Alupaneele an der Überdachung des both aluminium and steel. Eingangsbereichs Bahnhof Potsdam Besides building regulations, Strip-coated aluminium for the roofing of the enthe European guidelines © trance area at the train station in Potsdam near Berlin ALUMINIUM · 1-2/2008 ber dem Vergleichszeitraum 2006. Dieses Wachstum ist in erster Linie auf umfangreiche Lieferungen für den Bausektor zurückzuführen, wo bandbeschichtetes Aluminium z. B. für Wand-, Decken- und Dachprofile sowie für Verbundplatten, Türen und Tore eingesetzt wird. Die Konferenz stand unter dem Motto „European regulations, threat or opportunities for coil coating“. In diesem Zusammenhang wurde in mehreren Vorträgen aufgezeigt, welche Konsequenzen sich aus der aktuellen europäischen Gesetzgebung sowohl für die Bandbeschichter als auch für die Anwender bandbeschichteter Erzeugnisse ergeben. Ein Thema war der Einfluss der Europäischen Gesetzgebung auf den Bausektor, der sowohl für beschichtete Aluminiumwie für Stahlbänder der mit Abstand größte Einzelmarkt ist. Neben Regeln für die Bauausführung sind vor allem die europäischen Energie- und Emissionsschutzrichtlinien von Bedeutung. Gerade hier ergeben sich vielfältige Ansatzpunkte, die Vorteile von beschichteten Substraten als verkaufsfördernde Eigenschaften zu nutzen. Ein weiteres Thema waren die Auswirkungen der am 1. Juni 2007 in Kraft getretenen neuen EU-Gesetzgebung für Chemikalien – REACH – auf die weltweiten Lieferketten. Da die meisten der wichtigen Bestimmungen am 1. Juni 2008 wirksam werden, stellt sich für jeden Hersteller die Frage, wie er seine nachgelagerten Anwender unterstützen kann. Das Leitprinzip von REACH – „Ohne Daten kein Markt“ – bedeutet, dass alle europäischen Hersteller chemischer Stoffe ihre Produkte nur nach entsprechender Registrierung weiterhin anbieten dürfen. © 25 WIRTSCHAFT Strenger werdende Auflagen für den Umweltschutz stellen sowohl für die Hersteller, als auch für die Betreiber von Bandbeschichtungslinien eine große Herausforderung im Hinblick auf die Anpassung der traditionell auf der Verwendung von Chromat (Cr6+) beruhenden Vorbehandlung und Neutralisierung dar. Die neuen EU-Bestimmungen schränken die Verwendung von Cr6+ für Automobil(EU-Richtlinie EoVL) sowie Elektround Elektronikanwendungen (EURichtlinie RoHS) stark ein. Neben dem Einsatz des durchaus umweltverträglichen dreiwertigen Chrom (Cr3+) begünstigte die Gesetzgebung die Entwicklung chromatfreier Ersatzlösungen. Einige Beispiele wurden in Brüssel vorgestellt: Als Ersatz für chromhaltige Korrosionsschutzmittel zur Grundierung von Aluminium- und Stahlbändern eignen sich z. B. silikatische Pigmente mit Ionenaustausch. Bereits Mitte der 1980er Jahre wurden Pigmente auf Basis von Silikatprodukten mit Ionenaustausch als ungiftige und umweltverträgliche Alternative für die bislang bekannten Rostschutz-Pigmenttechniken auf den Markt gebracht. Inzwischen haben sich diese Produkte als eine viel versprechende Ersatzlösung für Chromate durchgesetzt und erlauben es der Bandbeschichtungsindustrie, Grundierungen entsprechend den angekündigten neuen europäischen Bestimmungen herzustellen. Als ein weiteres Beispiel für eine kostengünstige und qualitativ hochwertige Alternative zur chemischen Reinigung von Bändern wurde der Einsatz von „Openair“-Plasma vorgetragen. Im Gegensatz zu der bisher üblichen Wasser/Tensid-Reinigung der Bänder vor dem Auftrag einer Korrosionsschutzschicht handelt es sich hier um einen umweltfreundlichen Trockenreinigungsprozess, der die Energie von atmosphärischem Plasma nutzt. Damit können auch dünne Schichten von Schmiermitteln aus dem Walzprozess mit hoher Effizienz entfernt werden. Unter dem Motto „10 years into future“ findet die nächste ECCAKonferenz vom 18. bis 21. Mai 2008 in Malaga, Spanien, statt. B. Rieth, Meerbusch 26 on energy and emission protection are of importance. It is precisely here that there are many ways of using the advantages of coated substrates as sales-promoting properties. Another theme was the effects on the worldwide supply chain, of the new EU legislation on chemicals, REACH, that entered into force on 1 June 2007. Since most of the important provisions take effect from 1 June 2008, every manufacturer is faced by the question of how best to support his future users. The guiding principle of REACH – ‘No market without data’ – signifies that all European manufacturers of chemicals may only continue offering their products after appropriate registration. Stricter environmental protection impositions present a great challenge for both manufacturers and operators of strip-coating lines as regards protection media for the priming of aluminium and steel strips, for example silicate pigments with ion exchange are suitable. As long ago as the mid-1980s pigments based on silicate products with ion exchange were already brought onto the market as new, non-toxic and environmentally unobjectionable alternatives for the previously known rust protection pigment techniques. Now, more than 20 years later, these products have emerged as a promising replacement solution for chromates and are enabling the stripcoating industry to produce primers that comply with the announced new European provisions. As a further example of an inexpensive and high-grade alternative to the chemical cleaning of strips, the use of ‘Openair’ plasma has been proposed. In contrast to the previously usual water/surfactant cleaning Aluminium Centrum, Houten, Niederlande, mit bandbeschichteter Fassade Aluminium Centrum, Houten, The Netherlands, with strip-coated façade the adaptation of traditional pretreatments that rely on chromate (Cr6+) and its neutralisation. The new EU provisions greatly restrict the use of Cr6+ for automobile (EU-Guideline EoVL) and electric and electronic applications (EU-Guideline RoHS). Besides the use of the entirely environmentally unobjectionable trivalent chromium (Cr3+), the legislation also encourages the development of chromium-free alternative solutions. Some examples were proposed in Brussels: as a replacement for chromium-containing corrosion of strips before the application of a corrosion protection layer, this is an environmentally friendly, dry cleaning process which utilises the energy of atmospheric plasma and enables even thin lubricant films from the rolling process to be removed with high efficiency. The next ECCA Conference, run under the motto “10 years into the future”, will take place between 18 and 21 May 2008 in Malaga, Spain. B. Rieth, Meerbusch ALUMINIUM · 1-2/2008 WIRTSCHAFT Otto Rudolf Fuchs begeht 80. Geburtstag tiger Systeme: u. a. für Fenster, Türen, Fassaden, Wintergärten, Sicherheitsbauteile und Solaranlagen. 1964 geht im Meinerzhagener Werk die 30.000-Tonnen-Schmiedepresse in Betrieb, eine der weltweit größten privat finanzierten Schmiedepressen. 1966 steigt Otto Fuchs mit dem legendären Porsche-Flügelrad in die Großserienfertigung für geschmiedete Aluminiumräder ein. Otto R. Fuchs kann auf ein beeindruckendes Lebenswerk blicken, denn die Otto Fuchs-Gruppe gehört mit einem Umsatz von 2,2 Mrd. Euro zu den größten Mittelständlern Deutschlands. Nach wie vor ein Familienunternehmen ist der Unternehmensverbund heute mit der Herstellung von Hightech-Produkten für die Luft- und Raumfahrtindustrie sowie für die Automobil- und Bauindustrie breit aufgestellt und in zukunftsträchtigen expandierenden Märkten vertreten. Geboren wurde Otto R. Fuchs am 14. Januar 1928 im sauerländischen Meinerzhagen als Sohn von Hans Joachim Fuchs, dem geschäftsführenden Gesellschafter der Firma Otto Fuchs. Nach dem Studium des Maschinenbaus und Berufspraktikum in den USA tritt Otto R. Fuchs 1954 in den väterlichen Betrieb in Meinerzhagen ein, wo der zunächst die Abteilung Druckund Spritzguss (sog. Spritzerei) leitet. 1956 übernimmt er die Leitung des Zweigwerks Dülken, das in den sieben Jahren unter seiner Führung einen beachtlichen Aufschwung erlebt. 1963 tritt Otto R. Fuchs in die Geschäftsführung des Familienbetriebes ein und wird als weiterer Kommanditist der Gesellschaft aufgenommen. Es beginnt der Ausbau des Meinerzhagener Unternehmens zu einem international operierenden Konzern. Ein Jahr später erwirbt Otto Fuchs die Firma Heinz Schürmann & Co. aus Bielefeld: einen kleinen Betrieb zur Fertigung von Schaufenstern aus Aluminiumprofilen. Heute ist die Schüco International KG weltweit vertreten und Marktführer hochwer- Foto: Otto Fuchs KG Am 14. Januar dieses Jahres feierte Otto Rudolf Fuchs, eine der herausragenden Unternehmerpersönlichkeiten der Aluminiumindustrie in Deutschland, seinen 80. Geburtstag. Otto Rudolf Fuchs Otto R. Fuchs übernimmt 1974 die persönliche Haftung und damit die Leitung des Konzerns, der 1979 mit seiner Initiative um eine weitere Tochtergesellschaft, die Weber Metals Inc., Los Angeles, USA, erweitert und zu einer der führenden Aluminiumschmieden von Gesenk- und Freiformschmiedeteilen für die Luftfahrt ausgebaut wird. Nach dem Tod des Vaters im Jahre 1992 erfolgt eine Neuordnung der Beteiligungen an der Gesellschaft. Otto R. Fuchs und seine Halbschwester Christiane Fuchs übernehmen je 50 Prozent der Gesellschaftsanteile, die übrigen Gesellschafter scheiden aus dem Unternehmen aus. 1993 vollendet Otto R. Fuchs sein 65. Lebensjahr und beendet die Geschäftsführung als persönlich haftender Gesellschafter, begleitet jedoch weiterhin aktiv das Unternehmen als Kommanditist. Nach Überwindung der konjunkturellen Rezession Anfang der 1990er Jahre nimmt das Unternehmen wieder Fahrt auf. Mit dem größten amerikanischen Hersteller von gegossenen Aluminiumrädern gründet Otto Fuchs in Ungarn ein Joint Venture zur Herstellung von gegossenen und geschmiedeten Rädern für die europäische Automobilindustrie. Der Betrieb wird 1997 aufgenommen. Ein weiteres Joint Ventures folgt 2006 in Südafrika. Hier produziert Otto Fuchs in East London an der südafrikanischen Ostküste in Großserie Aluminium-Querlenker zusätzlich zu der Meinerzhagener Fertigung für einen ihrer größten Kunden: die Daimler AG. 2007 wird im Meinerzhagener Werk eine der modernsten Ringwalzanlagen in Betrieb genommen. Mit dieser Investition wird Otto Fuchs zu einem bedeutenden Anbieter von Triebwerksringen und -scheiben. Für seine persönliche und unternehmerische Lebensleistung und sein Engagement für das wirtschaftliche und gesellschaftliche Wohl der Stadt Meinerzhagen und seiner Bürger wird Otto R. Fuchs im Jahre 2003 das Ehrenbürgerrecht und der Ehrenring der Stadt Meinerzhagen verliehen. Zur Förderung des kulturellen Lebens in seiner Heimatstadt Meinerzhagen gründet Otto R. Fuchs eine Stiftung, die er mit einer Spende in Höhe von einer Million Euro ausstattet. Verwurzelt in seiner Heimat Meinerzhagen im südlichen Westfalen, ist Otto R. Fuchs nicht nur „aktiver“ Gesellschafter seines Unternehmens, sondern in seiner Freizeit unter anderem leidenschaftlicher Pferdezüchter. Aus seiner Zucht von Hannoveranern hat so manches Nachwuchspferd große Berühmtheit erlangt. Die Redaktion ALUMINIUM gratuliert nachträglich zum Geburtstag. N Bezugsquellen sinnvoll nutzen Auf den Seiten 112 bis 128 präsentieren führende Ausrüstungspartner der Aluminiumindustrie ihr Angebot. Nutzen Sie diese wertvollen Informationen! ALUMINIUM · 1-2/2008 27 WIRTSCHAFT EEG-Ausgleichsregelung für stromintensive Betriebe Ersparnisse von mehr als einer halben Milliarde Euro um 11,5 Prozent gestiegen. Auch die gereichten Anträge entschieden und Zahl der insgesamt bewilligten Bezum Jahreswechsel 2007/08 die Begrenzungsbescheide hat sich deutlich scheide versandt. erhöht (+15%). Hauptgrund für diesen Die BAFA setzt für jede antragsbeAnstieg dürfte sein, dass angesichts rechtigte Abnahmestelle individuelle steigender Strompreise eine wachProzentsätze fest. Diese bilden den sende Zahl von Unternehmen das eigentlichen Kern der Regelung. Sie Kriterium eines mehr als 15-prozenlegen für das jeweils folgende Katigen Anteils der Stromkosten an der lenderjahr fest, welcher Anteil des Bruttowertschöpfung erfüllt. an „privilegierten Abnahmestellen“ Zwischen den einzelnen Branchen bezogenen Stroms maximal aus EEGbestehen deutliche Unterschiede Quellen stammen muss, unabhängig beim jeweiligen Stromverbrauch. So von der jeweils im Folgejahr tatsächlich bezogenen Regelung Entlastungswirkung für die durch § 16 Strommenge. EEG begünstigten Unternehmen in 2008 In die BerechKonzessionsabgabe 1.300 Mio. Euro nung fließen dabei u. a. die Stromsteuer 800 Mio. Euro nachzuweiKWKG 60 bis 70 Mio. Euro senden tatsächEEG 650 Mio. Euro lichen Kosten des nicht nach Überschlägige Abschätzung der 2008 zu erwartenden finanziellen Nach dem EEG werden die Kosten EEG vergüteten Entlastungen bei den durch § 16 EEG begünstigten Unternehmen für den Ausbau erneuerbarer EnerStroms ein. Die gien auf die Stromverbraucher umhaben die begünstigten Unternehmen in den Bescheiden für die einzelnen gelegt. Für besonders stromintensive mit dem höchsten Stromverbrauch Abnahmestellen festgeschriebenen Unternehmen enthält das EEG eine aus den Bereichen Aluminium und Begrenzungssätze unterscheiden sich Ausgleichsregelung, mit der die ZuChemie jeweils einen Jahresstrombedaher in dem Maße, wie die Kosten satzlasten wieder ein Stück weit zuzug von mehreren Tausend GWh. des konventionell bezogenen Stroms rückgenommen werden. Durch eine Von der Regelung profitieren in bei den jeweiligen EnergieversorEnde 2006 in Kraft getretene Ändeder Branche „Erzeugung und erste gungsunternehmen differieren. rung des EEG beträgt diese Umlage Bearbeitung von NE-Metallen“ 19 Für 2008 hat die BAFA eine so für besonders stromintensive UnterUnternehmen mit einem privilegiergenannte privilegierte Strommenge nehmen inzwischen „lediglich“ 0,05 ten Letztverbrauch* von 10.653 von insgesamt GWh; in der Metallerzeugung und 75.874 GWh bearbeitung sind es 33 Unternehmen ermittelt, die mit einem Letztverbrauch von 1.966 nicht mit dem GWh. Die vier Branchen NE-Metalle, vollen, sondern Chemie, Eisen/Stahl und Papier stelbegrenzten len etwa drei Viertel des gesamten EEG-Anteil privilegierten Letztverbrauchs. abzunehmen Die BAFA führt darüber hinaus an, ist. Hiervon dass Sonderregelungen bei der Ökoentfallen etwa steuer, im Kraft-Wärme-Koppelungs94 Prozent gesetz sowie bei den Konzessionsab(71.283 GWh) gaben den privilegierten Strombezug auf UnternehBranchenverteilung des privilegierten Letztverbrauchs nach § 16 EEG für 2008 der 2008 begünstigten Unternehmen men des prozusätzlich in einer Größenordnung duzierenden von gut zwei Milliarden Euro (BAFAGewerbes. Diese Strommenge liegt Cent pro Kilowattstunde. Für eine Schätzung) verbilligen (s. Tabelle). damit etwa fünf Prozent über dem Aluminiumhütte summiert sich die Ergebnis des Bescheidverfahrens für Zahl hinter dem Komma dennoch auf 2007 (72.040 GWh). einen Millionenbetrag. Im Auftrag des * Beim sog. privilegierten Letztverbrauch handelt es sich um die Stromverbräuche, die die Die Zahl der begünstigten UnterBMU hat das Bundesamt für Wirtantragstellenden Unternehmen zur Jahresmitte nehmen liegt 2008 bei insgesamt 426. schaft und Ausfuhrkontrolle (BAFA) auf Grundlage des letzten abgeschlossenen Geschäftsjahres geltend machen. Sie ist damit gegenüber dem Vorjahr über die nach dieser Regelung einUnternehmen, die aus produktionstechnischen Gründen besonders viel Strom benötigen, werden laut Bundesumweltministerium (BMU) dieses Jahr erneut bei ihren Stromkosten entlastet, darunter 378 Firmen des produzierenden Gewerbes. Das Gesamtvolumen der Entlastung liegt 2008 laut BMU in einer Größenordnung von 650 Mio. Euro. Von der Ausgleichsregelung des ErneuerbareEnergien-Gesetzes (EEG) profitieren rund zehn Prozent mehr Unternehmen als im Vorjahr. Hauptgrund hierfür ist, dass angesichts steigender Strompreise eine wachsende Zahl von Unternehmen die Eingangskriterien der Regelung erfüllen. 28 ALUMINIUM · 1-2/2008 ECONOMICS ALUMINIUM · 1-2/2008 29 A L U M I N I U M S M E LT I N G I N D U S T R Y Primary aluminium activities at the turn of the year 2007/08 R. P. Pawlek, Sierre Africa During 2007, Dubai Aluminium Co (Dubal) signed a joint venture deal with Mubadala Development Co, Algerian energy company Sonatrach, and utility firm Sonelgaz to build Algeria’s first 700,000 tpy aluminium smelter on the west coast in the Béni Saf region with an investment of US$5bn. Rio Tinto Alcan signed an amended agreement with the government of Cameroon on access to water resources for the construction of a new 1,000 MW hydro power system in the West African country. That agreement paves the way for the start of technical studies on a potential 400,000 tpy greenfield smelter. A go-ahead decision on the smelter project is expected by the end of 2009. This project is separate from a previously-agreed study on the expansion of the existing 90,000 tpy Edea smelter operated as a joint venture between the government and Rio Tinto Alcan. The brownfield project, lifting capacity to 300,000 tpy, continues to make progress. Century Aluminum Co. signed a memorandum of understanding with the Republic of Congo for the exclusive right to develop a bauxite mine, alumina refinery and aluminium smelter. BHP Billiton signed an agreement with the government of the Democratic Republic of Congo (DRC) to jointly investigate the development of a 800,000 tpy aluminium smelter. Russia’s aluminium producer UC Rusal closed a deal to acquire a ma- 30 jority stake in the Aluminium Smelter Company of Nigeria (Alscon) in Akwa Ibom from the Nigerian Bureau of Public Enterprises. The transaction will add almost 153,000 tpy to Rusal’s aluminium production capacity. The smelter should go online by the end of 2007. Once fully operational, the smelter can provide up to 1,800 jobs. Furthermore, Rusal announced it could partner South African authorities in the construction of an energy and metallurgical complex. The South African government expressed interest in working with Rusal on the project, which would include building a 750,000 tpy capac- Alcan’s Kitimat smelter in British Columbia ity aluminium smelter and a 1,300 MW coal-fired power plant. Alcoa, USA, announced on 7 May 2007 Alcan signed a contract worth to make an offer to acquire all of the more than US$100m with a joint outstanding common shares of Alcan venture consisting of SNC-Lavalin, for US$58.60 in cash and 0.4108 of a Hatch, and Murray & Roberts for the share of Alcoa common stock for each front-end engineering design (FEED) outstanding common share of Alcan. and management of the first phase Based on Alcoa’s closing stock price of the proposed Coega Aluminium on 4 May 2007, the offer had a value of smelter (360,000 tpy). South African US$73.25 per Alcan share or approx. power supplier Eskom will take a 15% US$33bn in enterprise value, but was stake in the smelter. then outbid by Rio Tinto. On 12 July Rio Tinto announced its friendly US$38.1bn all-cash offer North America for Alcan. The offer of US$101 per share represents a 32.8% premium Alcan signed a US$130m contract to Alcoa’s offer of US$76.03 per with the French energy company share, based on Alcoa’s share price Areva for the design, engineering and of 11 July. Unlike Alcoa’s hostile bid, construction of a new high-voltage Rio Tinto has the backing of Alcan’s sub-station that will power Alcan’s board. On 25 October, Alcan and Rio planned AP50 pilot plant in Saguenay, Tinto group following the successful Quebec, Canada. offer for Alcan by a subsidiary of Rio Alcan also signed a contract with Tinto, became the global aluminium Bechtel to produce a detailed feasibilproducer known as Rio Tinto Alcan. ity study for the planned expansion The Alcan name was delisted on the of Alcan’s Kitimat smelter in British respective stock exchanges on 15 Columbia. Alcan announced its intenNovember. Rio Tinto is now itself tion to lift capacity at Kitimat from the the object of takeover bids: both BHP current 280,000 tpy to 400,000 tpy Billiton and China Investment © over a 2009 to 2011 timeframe. Photo: Rio Tinto Alcan This summary by continent reveals record global expansion with new smelters being built in areas where there is cheap energy. But there is also continued concentration of the market as major players merge or buy out others. This overview is divided into continents. ALUMINIUM · 1-2/2008 To power your operation while lowering consumption we provide you with stable highly efficient electrical energy supply, distribution and conditioning. To increase employee productivity and engineering efficiency, we offer you powerful control systems. To improve dynamic performance and reduce power losses, we provide high-tech drive systems. To increase furnace productivity and save energy, utilize our most effective electromagnetic stirrers. To ensure environmental compliance, reduce product standard deviation and increase production, apply our expert and optimization solutions. Maximize the return on project investment through our vast knowledge, know-how and extensive experience. Using quality ABB products helps you achieve industry leading productivity. Visit us at www.abb.com/aluminium A L U M I N I U M S M E LT I N G I N D U S T R Y Corporation have made rival bids. Alcoa’s Intalco smelter restarted a second potline at its Ferndale, Washington, operation. With the first molten metal poured, the operation’s capacity increased some 90,000 tonnes in 2007. The smelter has idled two potlines since April 2003, and the restart brings the plant’s output to 180,000 tpy, two-thirds of its rated capacity. Alcoa restarted one line at its Tennessee aluminium smelter. That line had been involuntarily idled due to a direct lighting strike in a severe electrical storm in mid-April. The potline produces about 107,000 tpy and was again fully operational at the end of June. Xstrata sold the aluminium business it inherited from its acquisition of Falconbridge in 2006 to private equity firm Apollo Management LP for some US$1.15bn in cash. Northwest Aluminum Specialties signed an agreement to dismantle the long-idled aluminium smelter it owns in The Dalles, Oregon and to restore the site. Northwest has contracted this work to Pro-SE Services Inc., a Californian company that specializes in engineering and demolition services, to be completed during 2009. In October Northwest Aluminum Co did not exercise its option to receive 100 MW of power from Bonneville Power Administration (BPA). As a result, the 100 MW will be divided proportionally between Alcoa and Columbia Falls Aluminum, owned by Glencore International. Alcoa received an additional 70 MW to bring it up to 390 MW and Columbia Falls will get 30 MW bringing its total to 140 MW. South America Argentine aluminium producer Aluar geared up to start bringing online its newly-constructed smelter expansion. The project lifted the plant capacity from 280,000 tpy to 410,000 tpy and energized 144 new cells. The first phase expansion, which added 130,000 tpy new capacity in an US$850m investment, was inaugurated on 3 September. Aluar confirmed it will move ahead immediately with a new US$400m investment at its Puerto Madryn smelter to raise primary alu- 32 minium capacity by another 105,00 tpy to 515,000 tpy by late 2009. Brazilian aluminium producer CBA started commissioning the next stage capacity increase at its Sorocaba aluminium smelter, expanding plant capacity from the current 405,000 tpy to 475,000 tpy. Cia Brasileira do Aluminio (CBA) announced it may expand its primary aluminium smelting capacity in Sao Paulo state to 700,000 tpy from the current 475,000 tpy. Alcoa announced investments in the Serra do Facaño hydroelectric power project to be built on the Sao Marcos River in Brazil’s central region. Alcoa will hold 35% of the new company. The investment is part of Alcoa’s long-term strategy of developing energy projects in Latin America to support its smelters and to move toward self-sufficiency for its energy needs. The president of Guyana used a trip to Moscow to sign a letter of intent with Rusal on the construction of an integrated aluminium complex in the South American country. Chinese alumina producer Bosai Minerals Group announced plans to construct an 800,000 tpy alumina refinery and 400,000 tpy aluminium smelter in Guyana. For this, Bosai Minerals intends to invest 10bn yuan (US$1.3bn) in building facilities and a 1,000 MW hydro power plant in Guyana within the next five years. The governments of Venezuela and Nicaragua announced a possible strategic alliance that could see the development of an aluminium smelter in Nicaragua. Studies are underway in Nicaragua to create a company to produce aluminium for the Nicaraguan and Latin American markets. A group of investors announced plans to build an aluminium smelter in the Republic of Suriname. Plans for the 250,000 tpy smelter were disclosed by Bisram Chanderbosh, president of Suriname Industrial Engineering & Vehicle Services. The second aluminium smelter project planned for the Caribbean country of Trinidad & Tobago was running late due to environmental concerns. The first project – the 340,000 tpy plant proposed by Alcoa – has already been put on the back-burner after the government was forced to back down on its proposed location under pressure from environmental lobbying. The second project, Alutrint, envisages a smaller 125,000 tpy smelter. UC Rusal and Corporacion Venezolana de Guayana (CVG) signed a letter of intent to explore alumina and aluminium projects in Venezuela. Asia Dubal and Mubadala Development Co, a wholly owned investment vehicle of the government of the Emirate of Abu Dhabi, signed a joint venture for the development of Emirates Aluminium (Emal), which plans to build a 1.4m tpy aluminium smelter in Abu Dhabi. Construction of the smelter is slated for two phases, the first of which is projected to cost US$5bn and the second US$3bn. The smelter is to be located at the Khalifa Port and Industrial Zone in Abu Dhabi. Rio Tinto also announced plans to develop a 550,000 tpy aluminium smelter together with Abu Dhabi Basic Industries Group (Adbic) at a cost of about US$5bn. Aluminium Bahrain (Alba) once more announced plans to raise aluminium smelting capacity by a further 320,000 tpy to more than 1m tpy, and is looking to expand through joint ventures in other Gulf countries. Alba intends to install a sixth reduction line at an estimated cost of US$1.7bn to take capacity to 1.2m tpy. Anshun Huangguoshu Aluminium Co, a privately-owned producer based in China’s southern Guizhou province, doubled capacity to 200,000 tpy. Guizhou Liupanshui Shuangpai Aluminium Co commissioned a 50,000 tpy project, doubling its total capacity to 100,000 tpy. In North China, Shaanxi Changhong Aluminium Co is building a 100,000 tpy aluminium project, scheduled to come on stream by June or July 2007. Aluminium Corporation of China (Chalco) announced plans to buy three other aluminium smelters. The acquisitions increase Chalco’s aluminium capacity and market competitiveness, Chalco’s listed subsidiaries Shandong ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U Aluminium Industry Co (SAIC) and Lanzhou Aluminium Co (LAC) said in separate statements. Chinalco is to buy 80% of the Inner Mongolian government’s wholly owned Baotou Aluminium group, which in turn owns 55% of BAC Chinalco, and received government approval to buy a 72% stake in Shaanxi Nonferrous Metals Group, which in turn owns 70.9% of Tongchuan, and is also to buy 100% in Liancheng. BAC produced 307,000 tonnes in 2006, Tongchuan 270,000 tonnes and Liancheng 155,000 tonnes. Chalco is looking to take full ownership of SAIC and LAC in a US$1bn deal that will enable it to list on the Shanghai Stock Exchange. China’s Aba Aluminium Plant in Sichuan province completed expansion works and double its ingot capacity to 40,000 tpy in June. Shanxi Guanlu Aluminium announced plans to expand ingot capacity by 100,000 tpy on its existing 200 kA line with 70,000 tpy current capacity. The third, a 300 kA potline with a I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 capacity of 200,000 to 220,000 tpy is a joint venture with Chalco (59%). Datun Aluminium in Jiangsu province started expansion works on its ingot capacity in 2007 which will lift capacity by 150,000 tpy to 260,000 tpy from the current 110,000 tpy. China suspended the construction of Qiya Aluminium Industry Group’s 150,000 tpy aluminium smelter, because it did not have the necessary environmental approval. Shanxi Zhenxin Group had to stop construction of the second phase of its 200,000 tpy aluminium smelter project after the environmental protection agency of China accused the company of flouting environmental laws. The first phase of the project, which was completed in 2002, remains in production. Century Aluminum Company signed a memorandum of understanding (MoU) with the Guangxi Investment Group Company (GIG) to explore the feasibility of developing an aluminium smelter project and related bauxite mine and alumina refinery in China. At least 14 people were killed and another 59 injured in a molten aluminium spillage at a casting plant owned by a subsidiary of China’s Weiqiao Aluminium. The accident happened on 19 August, when molten aluminium reacted with cooling water at the plant. The reaction caused an explosion of steam that blew the roof of the building, killing workers who were holding a meeting at the time. Alcoa sold its equity holdings in the Aluminium Corporation of China Ltd (Chalco) through a placement of shares for approx. HK$15.3bn (US$2.0bn). Chalco acquired Shaanxi Tongchuan Aluminium Co at the end of 2007. The acquisition of Tongchuan boosts Chalco’s aluminium by 250,000 tpy to 3.75m tpy currently. China’s Mimetals Corp’s alumina and aluminium arm, Minmetals Resources Limited (MRL) announced investments of 680m © C D C D m u i m n u i i min for Al um cassttiinngg Drache umwelttechnik ALUMINIUM · 1-2/2008 33 ALUMINIUM · 1-2/2008 33 A L U M I N I U M S M E LT I N G I N D U S T R Y yuan (US$90m) in Qinghai Province Investment Group(QIG), an aluminium smelter and hydropower producer. Vimetco acquired a Chinese aluminium producer with 110,000 tpy capacity for around US$35m. Majority-owned Henan Zhongfu Industry Co paid 266m yuan (US$35m) for Lifeng Aluminium, which is located in Linzhou, Henan province. Lifeng Aluminium has a workforce of 1,300. At the end of 2007, China announced guidelines for those who wish to enter the domestic aluminium industry, according to the National development and Reform Commission. All new development projects in the aluminium sector, including mining, alumina refining, primary smelting and recycling, as well as fabrication plants, must abide by all requirements of the various state departments. These include basic requirements for proper land use, safety and environmental regulations. Under the guidelines, smelting facilities cannot be built within 1 km of protected regions, which include: water preservation areas, protected farming areas, protected natural reservations, famous scenic attractions, major cities and their nearby surrounding countryside, hospitals, as well as food, medical and electronic business. For new primary smelting projects, approval is also required from the State Council’s investment management division. In the near term, only upgrading projects to suit environmental requirements and to replace outdated machinery are being considered for approvals. These projects also require guaranteed alumina feed supply, sufficient power supply, and efficient transport conditions. In February 2007, India’s top nonferrous producer Hindalco Industries agreed a friendly takeover bid for Novelis in a deal that values the North American aluminium company at about US$6bn, including about US$ 2.4bn of debt. Hindalco produces about 429,000 tpy of primary aluminium, and is planning a greenfield expansion that will take its capacity to 1.5m tpy by 2011. On 15 May Hindalco completed the US$6bn purchase of Novelis, which became a subsidiary of 34 Mumbai-based company. Hindalco Industries proved a coalmining joint venture to feed its much delayed 500,000 tpy integrated aluminium smelter project in Orissa. Emirate of Ras Al-Khaimah agreed a US$2bn joint venture with the government of Andhra Pradesh to build an alumina refinery and an aluminium smelter in the eastern Indian state. The alumina refinery will produce 1m tpy of alumina while the smelter will have an initial capacity of 250,000 tpy which may be doubled at a later date. Vedanta Resources announced plans to more than double capacity to 900,000 tpy of primary aluminium by 2009, once it has brought its new 500,000 tpy greenfield project in Orissa on stream. The smelter will be commissioned early next year and ramped up to reach full capacity in early 2009. The Indian aluminium producer Balco signed an MoU with the state of Chattisgarh on a major expansion of its Korba smelting complex. The MoU provides for a further investment of US$2bn to lift capacity by a further 650,000 tpy, bringing total capacity at the Korba complex close to the1m tpy level. Dubal and Larsen & Toubro proposed to jointly set up a 3m tpy alumina refinery and a 220,000 tpy aluminium smelter in the Indian state of Orissa. India’s state-owned National Aluminium Company (Nalco) announced plans to double its alumina capacity to 3m tpy and smelter capacity to 710,000 tpy. No time frame has been scheduled, but work towards these third-phase targets as well as a 700 MW power plant will begin at the end of 2008, when Nalco’s current expansion ends. Nalco is in the process of raising alumina capacity from 1.57m tpy to 2.1m tpy, and its smelter capacity from 350,000 tpy to 460,000 tpy. Ras-Al-Khaima Investment Authority (Rakia), a provincial investment company of the United Arab Emirates, is planning to invest US$2bn in a greenfield integrated aluminium complex in the India state of Andhra Pradesh. Rakia has singed an agreement with with the Andhra Pradesh Mineral Development Authority for bauxite reserves to feed a planned facility in Visakhapatnam. Rakia considers a 1.5m tpy alumina refinery and a 350,000 tpy smelter. The Indian aluminium industry expects to invest Rs1,000bn (US$25bn) over the next five years, boosting installed aluminium smelting capacity from the existing 1.1m tpy to 4m tpy. The announcement at the end of 2007 also said consumption of aluminium in India is growing at 18% per year compared with the global 4.4%. By 2015, the Indian aluminium use will grow to 2.75m tpy. In June 2007, India’s Nalco was looking for partners to set up a 500,000 tpy aluminium smelter project in Indonesia. However it was not revealed when the smelter might be built, or what kind of partnership Nalco was looking for. Iran Aluminium Company (Iralco) officially inaugurated its new Hormozal smelter to complement its existing 120,000 tpy Al Mahdi smelter. The first phase of the project has a capacity of 35,000 tpy and that will rise to 110,000 tpy when the second and the third phases are completed by March 2009. The expansion is being conducted in cooperation with China’s Non-Ferrous Metal Industry’s Foreign Engineering & Construction Company Limited (NFC). Gulf aluminium producer Dubal will supply its proprietary technology for an expansion of the Al Mahdi smelter in Iran. The Hormozal expansion of Al Mahdi will see the addition of a second potline with a capacity of 147,000 tpy, lifting total smelter capacity to 257,000 tpy Kazakhstan Aluminium Smelter (KAS), part of Kazakh metals and mining group Eurasian Natural Resources Corporation (ENRC), has signed a US$292.8m credit agreement with the Export-Import Bank of China (Eximbank). Building the smelter was complete by the end of 2007, and it will come on stream in three stages, with initial output at 62,500 tpy, rising to 125,000 tpy by 2008 and 250,000 tpy by 2011. UC Rusal was in talks with the Kazakh government about the possibility of building an aluminium and © ALUMINIUM · 1-2/2008 A L U M I N I U M S M E LT I N G I N D U S T R Y energy complex in the central Asian country. UC Rusal has approached the Kazakh authorities with a proposal to invest US$3.5bn in building a 500,000 tpy aluminium smelter and 1m tpy alumina refinery. UC Rusal resumed exploring opportunities for building an energy and metals complex in Kyrgyzstan, after its failure to accomplish a similar project in neighbouring Tajikistan. Rio Tinto announced it might sign an agreement with the Malaysian government for the construction of a 1.5m tpy aluminium smelter in the state of Sawarak. Many major aluminium companies around the world are said to be eager to participate in the project, including Alcoa and BHP Billiton, as well as China’s aluminium producer Shandong Luneng Group and energy company Sinohydro. In August Rio Tinto and Malaysia’s Cahya Mata Sarawak (CMS) signed a heads of agreement for the proposed development of a 750,000 tpy aluminium smelter in the Malaysian state of Sarawak. In October Bechtel had been appointed to undertake an engineering study of the proposed US$2.2bn new aluminium smelter. Alcoa was also in talks with the Malaysian government about the construction of a 1m tpy aluminium smelter in the state of Sarawak. Qatalum, the new aluminium smelter company in Qatar, a joint venture between Qatar Petroleum and Hydro Aluminium AS, has awarded the contract for its 1250 MW power plant to a consortium integrat- ed of General Electric and Doosan Heavy Industries Construction Co., Ltd. Qatalum will be a state-of-theart installation for 585,000 tpy of high quality aluminium using Hydro technology. The design incorporates an option to double the capacity to 1.2m tpy of aluminium. During the construction phase at the Mesaieed Industrial City, Qatalum will generate about 5,500 jobs, and once in operation during 2010, Qatalum will provide 1,000 permanent jobs. The capital investment estimate for the total Qatalum project is approx. US$5.6bn. Norsk Hydro and Qatar Petroleum laid the foundation stone on 19 November at the 1.7 square km site in Mesaieed Industrial City, south of Doha. Two Chinese state entities, China Non-ferrous Metal Industry’s Foreign Engineering and Construction Co Ltd (NFC) and China National Machinery Industry Corporation (Sinomach), signed an agreement with Saudi Arabian company Western Way for Industrial Development Co (WWIDC) to build an integrated alumina-aluminium mega-complex at Jazan in Saudi Arabia. The agreement provides for a project with an alumina capacity of 1.6m tpy and a primary metal capacity of 700,000 tpy for a total investment of around US$4bn. NFC will take a significant but as yet undisclosed stake in the complex, as will US metals trade house Gerald Metals. Alcan signed a heads of agreement with Saudi Arabian mining company Ma’aden to develop a US$7bn integrated aluminium mine-to-metal project, incuding bauxite mining, a 1.6m tpy alumina refinery, a 1,400 MW power plant and a 720,000 tpy aluminium smelter. MMC Corp and the Saudi Binladin Group signed an agreement with Aluminum Corporation of China (Chalco) to build a second aluminium smelter at Jazan Economic City (JEC) in Saudi Arabia at a cost of US$3bn. The smelter will have a capacity of 1m tpy. The companies formed joint venture company Sino-Saudi Jazan Aluminium Ltd to undertake the project, with Chalco and a Saudi consortium. Companies including Norsk Hydro are reported to be competing to become partners with Tajikistan’s sole aluminium produce Tajik Aluminium (Talco), which was once more likely to have been a target of their litigation. Having put its disputes with the smelter behind, Hydro is confident their new partnership will flourish. At the centre of both companies’ ambitions is the 500,000 tpy aluminium smelter, which has been running at 400,000 tpy in recent years. Hydro Aluminium will help modernize the smelter in exchange for increasing the volume of alumina it supplies to Talco. Dubai Aluminium (Dubal) announced plans to raise primary metal production capacity to 920,000 tpy by the end of 2008. After the US$230m ongoing potline 5B and 6B expansion, Dubal will further raise primary capacity to 945,000 tpy, and casthouse capacity to 1.13m tpy. At the end of 2007, Dubal announced plans to increase production to 2.5m tpy by 2015. Russia’s UC Rusal wants to build a hydro-electric power plant and an integrated bauxite-to-aluminium facility in Vietnam’s southern Binh Phuoc province. The planned aluminium smelter would have a capacity of 750,000 tpy. Photo: Norsk Hydro Australia Qatalum aluminium plant site 36 In October 2007, Rio Tinto’s takeover offer for Canadian aluminium producer Alcan received the green light from the competition watchdogs of Europe and Australia, and the US$38.1bn takeover created the world’s largest aluminium producer. ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 aluminium business in the Netherlands and Germany. Alu-Met, which is headquartered in Bludenz, Austria, has two production facilities in Germany. In Kempten Alu-Met produces 55,000 to 60,000 tpy of extrusion billet while in Nachrodt the capacity is about 80,000 tpy. The aluminium smelter in Voerde, Germany has a capacity of 90,000 tpy while the smelter in Delfzjil, the Netherlands has a capacity to produce about 110,000 tpy of primary aluminium. Carbone Savoie, a subsidiary of Alcan based in France, announced plans to invest US$17m to enhance equipment at the Notre-Dame-de-Briançon and Lannemzan sites in order to rapidly meet the needs of its cathode products customers. Anglo-Dutch steelmaker Corus Group, which is owned by Tata Steel, put its remaining primary aluminium business, which includes two smelters in the Netherlands and Germany, up for sale and has received an expression of interest from Trimet. In De- Rio Tinto obtained all outstanding common shares of Alcan and delisted Alcan on 15 November. In November investors seemed sure that mining giant BHP Billiton will continue its US$149bn pursuit of Rio Tinto, a combination that would control more than one third of the world’s iron ore sale. Rio Tinto rejected BHP Billiton’s 3-for-1 share offer on 8 November, but share price movements in London and Australia indicate investors expect that BHP Billiton will increase its offer, that the bid will turn hostile or that another bidder will emerge. BHP confirmed its approach to its mining rival and intends to continue to seek an opportunity to meet and discuss its proposal with Rio Tinto. Europe Alu-Met, Europe’s largest privately owned extrusion billet producer has thrown its hat into the ring as a possible suitor for Corus Group’s primary cember, Corus and Aluminium Industrial Acquisition Company Ltd (AIAC) signed a non-binding letter of intent for the proposed acquisition of Corus’ aluminium smelters by an affiliate of AIAC for an undisclosed sum. The German aluminium producer Trimet Aluminium AG restarted production at the idled aluminium smelter in Hamburg in April. Some 400 employees were recalled and the official opening was on May 9. End of 2007 all 270 cells were in full operation. Hydro Aluminium announced plans to build an aluminium smelter in Greenland with a capacity of as much as 300,000 tpy. Such a metal production would need 500 MW of power. The Greenland Home Rule Cabinet entered into an MoU with aluminium company Alcoa over co-operation on a feasibility study for a 340,000 tpy capacity smelter in Greenland. A planned expansion of Alcan’s smelter Isal in Iceland would see the implementation of Alcan’s AP35 © +( ,,#('%,+/#-(',.+('.#/ '!#'+#'! +(& ,##%#-2'!#'+#'!-( )%'-,#!''(',-+.-#(' (&)%--#%(+&)%'-, (+-" ,('+2%.&#'#.&#'.,-+2,(' ,--( -"+-(&)(''-,,.",-#%-% +(-+2+.& .+',,-#'! .+', ,-#'!&"#',"#)+2+,0#-"-" +%-.1#%#+2*.#)&'- +( ,,#('%+($-'!&'- (+ +-#('(&&#,,#('#'!')%'- &#'-'',0%%,-+#'#'!( ()+-#(' )+,(''%')%'-&'!&'- (+,-0!4 #+3#++&'2 (' 1 #%#' (%.-!&" 000%.-!&" A L U M I N I U M S M E LT I N G I N D U S T R Y 38 Alcoa opened its new 280,000 tpy prebake anode plant in Mosjoen, Norway. The facility produces anodes for Alcoa’s Fjardaal aluminium smelter in Iceland and for the Mosjoen aluminium smelter in Norway. The companies spent NOK3bn (US$528m) on the project, which employs 100 workers. once fully ramped up. UC Rusal started of a major modernisation programme at its giant Bratsk smelter, which with nameplate capacity of 983,000 tpy is the world’s largest single smelter. In November the Krasnoyarsk Aluminium Smelter completed the installation of automatic alumina Photo: UC Rusal technology, raising the total capacity to 460,000 tpy. However, Alcan lost its exclusive rights to power supplies which would have enabled the company to expand its Isal smelter. Alcoa started commissioning the 340,000 tpy Fjaardal smelter and celebrated the official inauguration at the beginning of June. To compensate for slight power project delays, Alcoa has secured some bridge power, but reached full capacity at the beginning of 2008. Century Aluminium of Monterey, California, is moving ahead with plans for its second smelter in Iceland. To be located in Helguvik, approx. 25 miles south of Reykjavik, the smelter would have an initial capacity of 150,000 tpy and could be expanded to 250,000 tpy. Since July, Century Aluminium’s 40,000 tpy has been commissioning the expansion at its Grundartangi smelter in Iceland. The ramp-up was completed at the end of November 2007, lifting capacity at the smelter to 260,000 tpy. Alcan sold its Vlissingen smelter in the Netherlands to Klesch & Company Ltd (Klesch).The transaction closed in summer 2007. The Vlissingen aluminium plant employs some 700 people and has a capacity of 200,000 tpy of primary aluminium, with a turnover of approx. US$600m in 2006. Hydro Aluminium of Norway announced investments of NOK 340m (US$55.74m) in expanding the four gas scrubber units at its aluminium plant at Sunndalsøra. The work will be complete by November 2008. On 13 June Hydro cut off power to the last Søderberg pots at its Årdal aluminium smelter. Capacity at Årdal fell from 220,000 tpy to 180,000 tpy as a result of the phase-out of the Søderberg potline. At the beginning of July the Norwegian Ministry of the Environment conceded temporary emission limits for the Søderberg aluminium production line at Karmøy. The limits are 3.2 kg/h for PAH (polycyclic aromatic hydrocarbons) and 35 kg/h particulates, and they postpone the closure of the Søderberg line until the end of 2009, when strict new emission limits come into force. UC Rusal’s Bratsk smelter In January 2007, Russia approved in principle the planned merger between Rusal, Sual and the alumina assets of Swiss trading company Glencore. The new company – United Company Rusal – will produce 4m tpy of aluminium and 11m tpy of alumina, with a workforce of some 110,000 people in 17 countries on five continents. The companies also obtained approvals from anti-trust authorities outside Russia. On 27 March 2007, Rusal, Sual and Glencore announced the completion of the deal to combine their assets and create United Company Rusal. UC Rusal and HydroOGK, Russia’s leader in the area of renewable energy, began construction of the Boguchanskiy Aluminium Smelter. The 600,000 tpy will be one of Russia’s five largest. Total investment in this project is expected to reach US$2.3bn. The foundation stone was laid on 15 May 2007 in the village of Tayozhny, Krasnoyarsk region. The construction of a fifth potline at UC RusAl’s Irkutsk smelter was on track for completion in the fourth quarter of 2007. The new line boosts the plant’s capacity from the existing 290,000 tpy to around 450,000 tpy point-feeders, having invested over US$38m. UC Rusal signed a cooperation agreement with the government of Russia’s Saratov region for the construction of a major energy and metals complex. The complex will include a significant expansion of the Balakovsky nuclear power plant, with UC Rusal building the fifth and sixth reactor blocks generating 2,000 MW, as well as the construction of the world’s largest aluminium smelter with a capacity of 1.05m tpy. UC Rusal signed an MoU on an integrated energy/aluminium complex with the local government of Sakhalin. Construction of a 2,300 MW power plant using coal from the Solntsevskiy coal mine would precede that of a 750,000 tpy smelter. At the end of 2007, UC Rusal announced its aim to lift annual aluminium production capacity to 6m tpy and alumina production to17m tpy by 2013. This represents a 50% increase in current metal production capacity. Some of that will come through upgrades to the existing smelter network, but more will come through greenfield smelter projects. N ALUMINIUM · 1-2/2008 S E ICN II UAML S M E L T I N G A LP UM INDUSTR TM Y S & ALUMINIUM INDIA 2008 Self-lifting crane modernizes older potlines D. Madden, Gladstone The design of many older smelters leaves no choice but to reline pots in situ. By contrast, modern smelters are designed with crane capacity, as well as built-in transfer facilities, so that they can complete pot relining outside the operating pot line. This increases production by a significant fraction, in order of 1%, worth millions of dollars. Southern Cross Engineering’s unique crane design is now finding its way into existing smelters previously constrained by their technology and/or building design. The crane and its operation This design is unique in that it is transported to the potline and there lifts itself onto the existing crane rails using an on-board hydraulic jacking system. The complete installation takes about one hour. The attached lifting beam can then lift the pot evenly. The crane is remotely operated by radio control, so allowing the operator to carry out all operations from the floor. Once installed, the crane is driven to the pot to be removed; there the pot is attached to the crane via the specially designed lifting beam, and is then lifted clear of the existing pot superstructures. The crane next transports the pot to the centre passageway, and loads it onto a trailer for transport to a pot dig-out building. The crane then picks up the new, relined replacement pot, delivers it to its position in the line, and installs it there. Turn-around time is approximately 2 hours. The crane finally lowers itself from the rails, and it is then removed from the potline hall and stored in a simple shelter, ready for re-use whenever needed. There are many important benefits of being able to remove the pot ALUMINIUM · 1-2/2008 39 Photo: Holcan An exciting new development allows smelters to remove and install whole pots complete with linings, using a crane design developed by Southern Cross Engineering (SCE) of New Zealand. and carry out the relining in a facility outside the pot line. The return on investment (ROI) is realised in a very short period, in some cases in months rather than years. With modern smelters pushing the envelope for ‘world’s best practice’ in areas of • Health and safety • Current efficiency • Lining life • DC kilowatts per tonne it is vital for the older smelters to be creative with their capital spending in order to capture the ‘low hanging fruit’ that offers high returns that are easily measured. With metal prices and metal demand at all time highs, any loss of metal production due to reconstruction time constraints becomes an important issue. Where are some of the costs incurred with reconstruction of pots in situ on the line? • Lost production, estimated at three weeks per pot • Power capacity paid for but not used • Daily potline operations disrupted • Hostile environment for potline workers • Low productivity due to working environment • Voluminous construction equipment encumbers the potline • Many construction personnel working in potline, creating extra safety issues for operation • Production labour paid for but not used. The following calculations show the benefits in monetary terms of completing this work outside the line for a typical smelter: These calculations are based on western world smelter costs, using the following assumptions: • Typical plant design Kaiser P69 • Tonnage 250,000 tpy with 500 pots • DC kWh/tonne 13,500 at 2.5 cents per kWh • Five year lining life with 100 relines per year • Pot production 1.4 tpd • Average reconstruction time per pot 18 days • LME price US$ 2,500 per tonne • 900 man hours to reconstruct pot at US$ 60 per hour • Based on 1,000 employees. Lost production 18 days x 100 pots = 1,800 pot-days 1.4 tonnes x 1,800 days = 2,520 tonnes of lost production US$ 2,500 x 2,520 tonnes = US$ 6,300,000 Lost production income due to reconstruction in the line is US$6.3m. Power paid for but not used 2,520 tonnes x 13,500 kWh per tonne = 34 million kWh at 2.5 cents/kWh = US$ 850,000 Power paid for but not used is US$ 850,000. © ALUMINIUM · 1-2/2008 39 A L U M I N I U M S M E LT I N G I N D U S T R Y Excess labour costs Estimated direct labour reconstruction productivity loss due to work constraints associated with working in an operating pot line; estimated reconstruction labour efficiencies captured by reconstructing outside operational pot line 20%: 900 hours estimated cost to reconstruct in pot line x 20% = 180 hours. Extra labour cost to reconstruct in line: 180 hours x US$ 60 per hour x 100 pots reconstructed per year. Extra labour cost is US$ 1,080,000. total production. Assume that 1,000 people are employed at the plant: 1% = 10 personnel. Cost per person per year US$ 60 x 40 hours x 52 weeks x 10 employees = US$ 1,248,000 per year. Extra production labour cost per year is US$ 1,248,000. Aggregation: US$ 9,478,000 per year additional income through usefully employing otherwise wasted resources of electrical power and production labour. Conclusion Plant production labour paid for but not used 2,520 tonnes lost production = 1% of Smelters that currently complete pot reconstruction in the pot lines should take a close look at this crane. This article has only touched the surface of the benefits, focussing on direct monetary savings. The long-term considerations associated with workers’ health have not been factored in. Disclaimer A study of the smelter’s pot room structure would need to be carried out to verify its compatibility with the installation and operation of the new crane. Author Dan Madden is the Managing Director of Holcan Constructions. He has been associated with the primar smelting industry for over 30 years. Hydraulic pressing of prebaked anodes for aluminium smelters A. Kaiser, Wecke There have been very few direct comparisons between vibrated and pressed anodes [4]. Several production plants operate both hydraulic presses and vibrocompactors, but produce different types of anodes with each forming process. The few available data can be 40 summarized as follows: pressed and vibrated anodes show similar average values, e. g. comparable apparent density levels (green and baked). On average, pressed anodes (shaped on ‘old’ hydraulic presses) have lower air permeability, whereas vibrated anodes show better specific electrical resistance and strength values. The new Laeis pressing concept [5] over- comes these disadvantages in electrical resistance and strength, while maintaining the advantages. The new Laeis hydraulic vacuum press for anodes Dosing and weighing unit: The cooling mixer continuously discharges conditioned and homogenized paste into a Illustrations: Laeis Even though vibrating compaction has long been the most common means of forming prebaked anodes, many plants worldwide still use hydraulic pressing. Improvements in hydraulic pressing technology are now available for prebaked anode production and may lead to a revival of this well proven, but temporarily unfashionable technology. Laeis, a world leading supplier of high performance hydraulic presses [1,2] originally developed these improvements for other applications. The new anode forming concept uses a hydraulic vacuum press [3] and offers advantages in process productivity and flexibility, as well as in anode quality and environmental impact. Fig. 1: Schematic drawing of different pressing principles left: bilateral pressing, middle: HPF pressing principle, right: unilateral pressing ALUMINIUM · 1-2/2008 S E ICN II UAML S M E L T I N G A LP UM dosing unit; this feeds a weighing bin which measures the paste needed for the next pressing stroke. The dosing and weighing unit maintains an overall dosing accuracy of ±5 kg and can Parameter Pressing force max. Useful die surface max. Filling depth max. Time per stroke min. Throughput capacity (1 or 2 cavities) Height accuracy Vacuum Pressing temperature (approx.) Noise level Mould changing time INDUSTR TM Y S & ALUMINIUM INDIA 2008 work with cycle times of about one minute. It can be designed as single or as a twin unit to be used for 1-cavity respectively 2-cavity moulds, depending on the size of the anodes to Unit Value kN t mm x mm mm min pcs/h mm mbar °C dBA h 16,000 1,600 1200 x 1800 1200 ≥1 ≥ 60/120 ±2 < 100 110-130 ≤ 76 ≤1 Table 1: Performance data of hydraulic anode press MEGA 1600 AV Fig. 2: Influence of vertical density distribution in a pressed product Fig. 3: Main menu of ProVi press control showing the graphic orientation of the machine/operator interface ALUMINIUM · 1-2/2008 41 be pressed. A reversible conveyor allows scrap paste to be discharged (e. g. during start up of the process) without it going through the weighing system and the press. Hydraulic vacuum press: A high performance hydraulic press type MEGA 1600 AV is used for the shaping of the anodes. It belongs to the well known Laeis HPF press series with the so-called ‘active mould’ movement which has been proven as state-of-theart presses in the refractory industry for many years. Together with a very flexible control system, the HPF pressing principle (Figs. 1 and 2) provides the advantages of a bilateral pressing system (optimum densification and controlled density distribution over the height of the anode), but avoids the traditional disadvantages of such presses (deep pits up to 6 m necessary, high costs for foundation works). The MEGA 1600 AV with a pressing force of 16,000 kN (1,600 t) has been specifically adapted for the production of prebaked anodes. For instance, it features an extended die surface area for pressing anodes up to about 1700 mm long, about 1200 mm wide and maximum 1200 mm deep, so as to form anodes of practically all dimensions used today. The mould design allows direct pressing of stub holes for rodding of the anodes. A special mould filling device ensures homogeneous filling of the pre-weighed paste into the mould (1 or 2 cavities) and a vacuum system evacuates air from the mould before compaction. A special mould changing device is available which can complete a mould change in less than one hour. The main performance data of the MEGA 1600 AV press are summarized in Table 1. Press control: The flexible press control system allows a fully automated and safe plant operation. It also collects and stores comprehensive data, and it provides for comfortable evaluation using standard software for individual data processing. The operator interface has a clear and easy-to-understand structure designed around Windows technology with mainly graphic display (Fig. 3). When anodes are pressed, the press continuously monitors the height of each an- © ALUMINIUM · 1-2/2008 41 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 4: Pressing regime for pressing to nominal anode height ode and the applied pressure. Different pressing regimes can be selected, but for the production of anodes the standard mode is ‘pressing to nominal height’ (Fig. 4). Many individual pressing parameters can be set and/or changed in order to optimize the pressing sequence and the resulting anode properties. Table 2 shows some of these parameters and their main effects. The control system additionally provides communication links with external systems, such as upstream and downstream plant components as well as host computer. These links can be used in many different ways, such as for plant operation supervision as well as for quality control, documentation and statistical evaluation. Advantages of hydraulic pressing of anodes Plant productivity and flexibility: One of the most important features of the hydraulic press MEGA 1600 AV is its high production capacity of up to 60 or 120 anodes/h (1- or 2-cav- ity mould) in a single line. For most anode sizes it can form up to 50 t/h or even more. Two additional factors contribute to the plant’s exceptionally high performance: • The press needs only short downtimes for maintenance, thanks to its heavy duty design and to the reliable pressing technology (no vibration). Typically two weeks downtime suffice per year for preventive inspection and maintenance. • Mould changes take only a very short time. The special mould changing device ‘Hydrofast’ performs a complete change of the mould within less than one hour. This is especially important for anode producers who supply anodes of various formats and sizes to different customers and who therefore frequently need to change the mould. Product quality: An important feature of hydraulic presses in general, and of the HPF presses in particular, is the extreme dimensional accuracy which they can achieve. Despite the relative- Parameter Charger moving speed Charger movement Mould moving speed during filling Plunger speed (multiple adjustable) Mould frame movement relative to plunger movement Vacuum application (time, duration, final vacuum) Pressing speed(s) Pressure increase speed limitation High pressure holding time, pressure relief Anode ejection (with or without load; load weight) ly large height of the typical anodes and the corresponding long densification stroke of the press plunger, these presses guarantee a deviation in anodes height of less than ±2 mm. The special HPF pressing principle, together with the vacuum pressing technology, provides optimum densification and even density distribution within the anode. Pressing under vacuum can be expected to lead to several advantages such as: • Higher green density of the anodes • Higher green strength of the anodes, which can be pressed and handled at higher temperatures than when pressing without vacuum • Lower electrical resistance, which is aggravated by entrapped air • Less density variation in vertical direction within the anodes. In general, hydraulic presses can form anodes at much lower temperatures than can vibrocompacting (typically 30 to 40 K lower). This again contributes to a higher strength and dimensional stability of the green anodes Effect Cycle time; homogeneity of mould cavity filling Complete discharge of paste batch into mould cavity Cycle time; even cavity filling Cycle time; paste densification; density distribution Paste densification; density distribution Cycle time; paste densification Cycle time; paste densification Cycle time; paste densification Cycle time; paste densification; anode back expansion Cycle time; anode back expansion Table 2: Press control parameters to be set and/or changed by the operator 42 ALUMINIUM · 1-2/2008 S E ICN II UAML S M E L T I N G A LP UM (no bulging) and avoids the need for additional water cooling of the anodes after forming. Environmental impact reduction: The low forming temperature reduces the environmental impact of anode manufacture in several ways: • As mentioned above, anodes need no water cooling, thus saving direct investment costs and running costs, but also reducing water consumption and avoiding contamination of cooling water • There is less emission of volatile pitch components (especially PAHs) from the forming area, thus improving the working environment. Exhaust connections at all critical points minimize air pollution and can be combined with existing air cleaning systems. Another remarkable contribution to environmental impact reduction and labour comfort is the low noise level of the MEGA 1600 AV with ≤ 76 dBA. INDUSTR TM Y S & ALUMINIUM INDIA 2008 Summary A new hydraulic pressing concept for anodes has been developed with the Laeis hydraulic vacuum press MEGA 1600 AV. It is based on state-of-the-art pressing technology with matching plant components for paste cooling and conditioning, dosing and weighing units as well as for other peripheral equipment. This press can produce highest quality anodes of all sizes required today, and has an unmatched production capacity of up to 50 t/h or higher in a single line. A high plant availability, together with low maintenance costs and reduced environmental impact, make this technology attractive for anode producers. modern pressing technology; Preprints 49. Internat. Colloquium on Refractories (2006), 223–226. [2] R. Lutz: Use of closed loop controls in hydraulic press forming of ceramic products to obtain highest dimensional accuracy; Stahl und Eisen Special, Refractories in Steelmaking, 47. Internat. Colloquium on Refractories (2004), 222–224. [3] W. K. Fischer and M. W. Meier: Advances in Anode Forming; Light Metals (1999), ed. C. E. Eckert (TMS, Warrendale, Pa), 541-546. [4] K. L. Hulse: Anode Manufacture – Raw Materials, Formulation and Processing Parameters, Ph. D. Thesis, R&D Carbon Ltd., (2000). [5] A. Kaiser: Hydraulic pressing promises better anodes, Part I, Aluminium 80 (2004) 3, 192-198, Part II: Aluminium 80 (2004) 4, 276-281. Author References [1] R. Kremer and R. Lutz: Quality improvement of shaped refractories by Dr. Alfred Kaiser is Manager Business Development of LAEIS GmbH, based in Wecker, Luxembourg. Visit us at TMS 2008 Booth #211 ALUMINIUM · 1-2/2008 43 ALUMINIUM · 1-2/2008 43 A L U M I N I U M S M E LT I N G I N D U S T R Y Zero fuel baking – the total heat recovery concept W. Leisenberg, Butzbach Fuel costs are going up rapidly, and to protect the environment emissions of greenhouse gases must be as low as possible. The ‘Total Heat Recovery Concept’ will be a big step towards meeting these requirements. It will bring the anode plant and also the electrolysis to a more efficient state of thermal energy efficiency, especially in combination with a thermal power station. heat as the anode reaches 1100°C at the end of the soaking time. In practice we also heat up the baking furnace structure and the packing material, so the real baking process needs much more energy as shown in Fig. 2. Not all of that stored heat can be recovered, because the anodes usually are unloaded at a temperature of about 200°C. Therefore some residual heat is left in the anodes, in the refractory and in the packing coke, as shown in Fig. 3. The greenhouse gas situation Baking furnace heat balance Today open pit horizontal flue ring Illustrations: innovatherm Since the anode is the biggest source of CO2 evolved from the smelter, great efforts have been made to replace the carbon anode by non-consumable electrodes, but without significant impact so far. But is the carbon anode technology really such a bad technology with regard to the environment? The most electrical energy world-wide is generated from fossil fuels in thermal power stations. The energy efficiency of this conversion process is below 50 percent. By contrast, the chemical efficiency of the carbon anode in HallHéroult electrolysis is 60 percent. If we need to use fossil fuel anyway, why not use it with such a high efficiency as has the carbon anode in the smelter? Finally, compared to non-consumable electrodes, the overall greenhouse gas mass balance for carbon anodes suggests that no other technology shows a higher efficiency. This technology includes a most efficient use of fuel for calcining of the carbon anodes; and there is a really considerable potential left for heat recovery. furnaces are used for anode baking. The principle of the ring furnace is to internally recycle some of the heat stored in the cooling area. In terms of heat flow, the ring furnace consists of two convection heat exchangers with a firing zone between. In the first heat exchange process, cold air is blown into the cooling area and is heated by hot anodes, packing material and furnace structure. This air then passes into the firing zone as preheated combustion air, becomes flue gas, and further downstream it transfers the majority of its heat content to the cold anodes. Fig. 4 shows the heat balance of a baking furnace typical Fig. 1: Anode baking heat balance Fig. 2: Total stored heat Anode baking heat balance As shown in Fig. 1, anode baking is a highly exothermal process. The quantity of tar pitch fed to the process represents far more energy than is needed to bake the anode [1]. In theory the baking process as such requires less than 350 MJ/t of anode. Most of the energy is stored as 44 Fig. 3: Residual heat ALUMINIUM · 1-2/2008 S E ICN II UAML S M E L T I N G A LP UM Fig. 4: Baking furnace heat balance Fig. 5: Improved furnace design and control INDUSTR TM Y S & ALUMINIUM INDIA 2008 for the situation twenty years ago. Firstly we can see that little or no tar pitch burns, so its energy is mostly lost. The furnace design was not optimized, and so the fuel consumption was as high as 3300 MJ/t of anode. A great amount of waste heat – 1900 MJ/ t – blows from the cooling area into the furnace hall. The heat balance of the furnace is completed by the various other losses from the furnace. The end of the 20th century saw improvements in furnace design, such that impulse firing technology, and control of both the firing zone and preheat area became state-of-the-art. Due to the higher homogeneity of the pit temperatures, the peak temperature of the flues could be reduced from nearly 1300 to less than 1200°C. This lower peak temperature, together with lower refractory mass of the furnace structure, led to a lower stored heat in the cooling area (Fig. 5) and finally to lower the fuel consumption, down to typically 2400 MJ/t [2]. A further big step in reducing of fuel consumption was the ‘Complete Pitch Burn Technology’ introduced by Innovatherm in the last few years [3]. By using practically all of the energy in the tar pitch, this technology has reduced fuel consumption dramatically to a bench mark of 1800 MJ/t today (Fig. 6). We see from the Sankey diagram shown in Fig. 6 that a lot of heat is still not used. Part of this waste heat blows from the cooling area into the furnace hall, creating oppressively hot ambient temperatures especially in hot countries. The other part leaves the furnace with the flue gas. Since not all the heat content of the volatiles can be kept in the baking process, the waste gas temperature is about 100°C higher than with incomplete pitch burn. Heat recovery Fig. 6: Baking process with ‘complete pitch burn’ ALUMINIUM · 1-2/2008 45 Obviously there is a lot more surplus heat available from the baking furnace, so two questions arise: how can we take that heat from the furnace and where can we use it? The answer to the ‘where?’ is: coke heating in the paste plant is the only major heat sink in the anode © ALUMINIUM · 1-2/2008 45 A L U M I N I U M S M E LT I N G I N D U S T R Y plant. About 200 MJ/t are necessary to heat the coke to about 150°C, including some heat for supplementary equipment. Regarding the ‘how?’: if we look at a simplified Sankey diagram for the baking process, including the fume treatment plant shown in Fig. 7 we will find that the flue gas and the waste heat in the cooling area are the two main heat sources. A technology to use the heat of the flue gas in the paste plant has been proposed by the author earlier [4]. But this concept is hardly accepted because the paste plant would need serious modification due to the relatively low temperature of the flue gases. So the energy now is deleted in the conditioning tower of the fume treatment plant (FTP). The paste plant needs higher gas temperatures if its technology will not be changed. As shown in Fig. 5, the ring furnace recovers some heat from the cooling area. Another small part disappears as heat loss due to radiation, convection and ‘blow-out’ of hot air via leakages, or remains as residual heat in the anodes, the packing material and the refractory. The balance heat of 1200 MJ/t blows into the furnace hall. In order to create an energy link, the thermal transfer oil for the paste plant collects the baking furnace waste heat from the cooling area. This thermal transfer oil then serves as a heat supply for the heating screw and the kneading/mixing plant. To realize this recovery technology, firstly one of the two blower ramps in the cooling area is replaced by an exhaust ramp. So there is no change in the number of equipment units on the furnace or in the investment costs, as shown in Fig. 8 Further, a second hot air duct, besides the flue gas duct, is installed to collect the hot air from the cooling areas of all fires and to direct it to a heat exchanging unit. Here the hot air gives its energy to the thermal transfer oil for the paste plant (Fig. 9). The heat exchange unit is not subject to corrosion because the hot air from the cooling area is not contaminated by any corrosive or acid fumes. Since the temperature of the air taken from the cooling area is about 46 Fig. 7: Heat balance including fume treatment Fig. 8: Cooling area equipment 400°C, it easily provides the thermal oil temperature of 300°C which the paste plant needs. This concept supplies all thermal energy required from the paste plant without changing the proven paste plant technology. For start-up operation or to bridge any temporary lack of heat, a heat generator is placed in the hot air duct. So the boiler for the thermal transfer oil in the paste plant, including its stand by unit, is eliminated completely. The overall investment costs are kept the same. Of course, the hot air, after passing the heat exchanger, can be re-used for other purposes such as for coke drying or for building heating in cold countries. Total heat recovery concept A complete heat recovery can be realised in a second step if a thermal power station is located near to the smelter. Every thermal power station heats water for the boiler to generate steam for the turbines. The amount of water required is so large, and the temperature of the fresh water is so low, that it acts as an ideal heat sink to recover any remaining heat from the furnace. Even a portion of the whole amount of water will suffice to recover all waste heat of the baking process. The remaining heat of the hot air from the cooling area can easily be extracted by installing a second heat exchange unit downstream from the unit for the thermal transfer medium (Fig. 10). The water for the power station can also recover residual heat from the flue gas. A two-step heat exchange plant transfers all usable heat to the water. This cools the flue gas to about 130°C as it enters the fume treatment ALUMINIUM · 1-2/2008 S E ICN II UAML S M E L T I N G A LP UM INDUSTR TM Y S & ALUMINIUM INDIA 2008 then each recovered Joule saves 11 percent more fuel at the power station respectively at the paste plant. The equivalent-to-fuel heat recovery then is nearly 1900 MJ/t, which is more than what the baking furnace requires as fuel. This means that the baking process, including all losses, is virtually fed by tar pitch only and can be considered to run at zero fuel. This concept will set a new benchmark for the fuel efficiency in aluminium smelters. Summary Fig. 9: Coke heating by hot air from cooling area With the ‘Total Heat Recovery Concept’ technology considered in this paper, the fuel efficiency of the anode baking process can be brought very close to the theoretical limit of running at zero fuel. All equipment which is necessary for this concept is proven and available today. References [1] B. J. Racunas: Anode baking furnace thermal balance, Light Metals 1980, ed. H.O. Bohner (TMS, Warrendale, Pa). [2] Alcan/AP, Inst. Paul Heroult: Anodes Baking, AN 3 5 CAEN V3, 2004. [3] W. Leisenberg: Firing and control technology for complete pitch burn and its consequences for anode quality, energy efficiency and fume treatment plant, 9th Intl Conf. on Non Ferrous Metals, July 8-9, 2005, Pune. [4] D. Maiwald and W. Leisenberg: The development of anode baking technology from past to future, Light Metals 2007, ed. M. Sørlie (TMS, Warrendale, Pa), pp. 947952. Fig. 10: ‘Total Heat Recovery Concept’ plant. A lower flue gas temperature is undesirable because acid components would condense at the dew point of the waste gas. As a side effect, the flue gas temperature will be kept constant ALUMINIUM · 1-2/2008 47 and so minimise the demand of water in the conditioning. If we assume about 90 percent efficient heat transfer to the boilers in the power station and in the paste plant, Author Prof. Dr. Wolfgang Leisenberg is Director of innovatherm Prof. Dr. Leisenberg GmbH u. Co. KG, Butzbach, Germany. ALUMINIUM · 1-2/2008 47 A L U M I N I U M S M E LT I N G I N D U S T R Y Best available technology for the fume treatment of anode production plants M. Hagen, B. Schricker; Goldkronach The new IPPC regulation [1] as well as local legislation force aluminium manufacturers to improve their air emission control systems. Furthermore a critical neighbourhood puts pressure on plant managers to think about the future of their plant. Type of emissions In order to design an appropriate fume treatment system we need to know the type and amount of pollutants. The two main processes which generate air emissions from anode production plants are: paste production and baking. Even if the rough numbers seem to be equal, there are huge differences in emissions from paste plants compared to baking furnaces. The reason is mainly the different temperature at which the fumes are generated. The most important factors for paste plants are: • Type of mixer • Type of cooler and amount of cooling water/temperature • Mass of produced paste • Additional connected sources. The most important factors for baking furnaces are: • Type of furnace (open or closed type baking) • Production cycle and output • Type of fuel and firing system • Raw materials for anodes (e. g. HF due to re-use of butts; SOx due to sulphur content 0.5 to 4%). Table 1 (next page) shows the range of possible emissions at furnaces without a fume treatment. In particular the polycyclic aromatic hydrocarbons (PAHs) are critical target substances for the design of a RTO, especially those PAHs which consist of more than two benzoic rings. Depending on the temperature they can appear as volatile gases or as condensed particles. Fig. 1 shows an example analysis of PAH- © Illustrations: LTB Aluminium production plants have several sources of emissions. Dust emissions are trapped using bag house filters for many years. For the additional adsorption of HF, recycled from the electrolysis cells, these filters have been equipped with alumina injection. All these systems are stateof-the-art and are accepted as ‘best available technology’. Based on this favourable experience, companies often copied these fume treatment systems for the abatement of particulate pitch and tar fumes coming from the baking furnace and from paste production. But the pitch and tar at high temperatures also generates other volatile emissions, which potline filters cannot treat. These fumes contain a mix of odorous and carcinogenic substances, known as polycyclic aromatic hydrocarbons (PAH). For these volatile compounds, as well as for condensed particulates, a fume treatment system based on regenerative thermal oxidation (RTO) is the ‘best available technology’ according to the IPPC. The aim of LTB was to create an abatement system, capable of fulfilling the emission control levels even in the long term. During three years of testing with a small plant and of running a full scale pilot unit LTB created a specific ‘Carbon design’RTO. In order to explain the details of this special design this article will again present the basic principles of RTO. Fig. 1: Composition of PAH emission from a baking furnace (example) 48 ALUMINIUM · 1-2/2008 A L U M I N I U M S M E LT I N G I N D U S T R Y Anode specific flue gas volume CO Total carbon Tar/condensates PAH Soot/dust SOx HF open type close type furnace furnace 5,000 3,500 m3/t mg/Nm3 mg/Nm3 mg/Nm3 mg/Nm3 mg/Nm3 mg/Nm3 mg/Nm3 < 1,200 < 1,500 100-300 < 1000 200-400 800-1,200 20-200 40-500 100-200 50-100 100-800 100-800 5-300 5-300 Tab. 1: Typical gross emissions during anode baking [1] containing flue gas containing various amounts of particulate and gaseous matter (PAH listed with increasing boiling point from left to right). A typical example in the middle of the PAH list is benzo(a)pyrene, which has five rings, a molecular weight of 252 and a boiling point of 496°C. As Fig. 1 shows, the substances with a lower molecular weight are mostly gaseous under the conditions of a furnace. Therefore a large part of them will burn already in the furnace (especially in the open type furnace). With increasing boiling temperature, most of the PAH appear solid or condensed (Fig. 1). Historical background and state-of-the-art technology To trap particle emissions, electrostatic precipitators (ESP) have often been used. To improve the efficiency of these ESP in trapping condensed tars, lots of them have been equipped with an upstream cooler. Based on stricter limits for the total carbon emissions imposed during the late 1980s, new systems have been developed [3]. Their design was similar to the fume Fig. 2: LTB RTO test plant [2] treatment centres of the electrolysis pots, using a dry scrubbing process with alumina as an ab- and adsorbent to eliminate the particulate pollutants. Due to complaints from neighbours and to stricter emission limits, in the 1990s volatile compounds and odour started to get more and more critical attention. In Europe an increasing number of countries reduced the legal limits for polycyclic aromatic hydrocarbons (PAH) especially benzo(a)pyrene, which is supposed to be carcinogenic. The only known technology to reduce these PAH, as well as total carbon, below the required limits is a thermal oxidation. Ideally this thermal oxidation plant is equipped with a regenerative heat exchanger so as to recover most of the energy the process requires. Already in 1994 the German Environmental Protection Agency started a test plant in Germany to reduce PAH emissions downstream of an electro- static filter [4]. In the late 1990s a German company entered the market with an RTO system. Two plants were built but had huge problems due to clogging of the valve system. Since 2005 a combination of prefilter, RTO and packed bed filter (for HF adsorption) treats the emissions of an open type furnace in the Netherlands. In 2004 LTB started to operate a test plant in the bypass of a closed type baking furnace. Closed furnaces generally produce very concentrated emissions compared to open type furnaces (see Table 1). The target of the test runs was to check the basic cleaning efficiency and to find an appropriate design for the valve system. As the valve system is an essential component of a low emission system, it has to work reliably even under the heavy pollutant load coming from a baking furnace. The tests showed that the destruction of total carbon in the RTO is not a problem at sufficient burning tem- Fig. 3 and 4: Redundant prefilter system 50 ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 Fig. 6: Ceramics before bake out Fig. 5: 4-chamber RTO for continuous burn-out with separate burn-out fan peratures (Fig. 3). But the tests also showed that the almost complete destruction of the PAH is a very ambitious task. The test plant reached a cleaning efficiency of single PAH compounds between 88 and 98%, depending on the concentration and the type of PAH. But a pre-cleaning filter is necessary to increase the overall efficiency above 97%. This can be done, for example, with a fixed bed filter which collects the condensed PAH fraction. As this filter will accumulate condensables and tar, it has to be cleaned periodically. Therefore two redundant fixed bed filters have to be installed to enable continuous operation by cleaning the fume gases in one filter during purification of the other prefilter (Figs. 3 and 4). An alternative filter could be an electrostatic precipitator (ESP), which often already exists at anode production plants. An opposite approach is to increase the temperature of the flue gases entering the RTO by changing the burn- Fig. 8: Valve box design ALUMINIUM · 1-2/2008 51 ing curve or even by adding a heater. As tests from LTB prove, this will only lead to increased energy consumption but not to a significant reduction of the PAH load. The reason is the very high boiling temperature of many PAHs which usually is much hotter than the flue gas temperature of the furnace, and so cannot be reached with only a moderate increase of the flue gas temperature. For this special kind of flue gas composition (Fig. 1) LTB therefore has focused on the development of a highly efficient pre-filter system in combination with an optimized burnout mode. Current LTB developments During operation of a conventional RTO-plant, tar and other high-boiling hydrocarbons, tend to deposit and accumulate on the inner valvebox walls and on the inlet surface of the ceramic heat exchanger blocks (Fig. 6). This condensate compromises cleaning Fig. 7: Ceramics after bake out efficiency in two ways: the pressure drop of the plant increases, and the higher gas velocity will partially strip off precipitated tar from the valveboxwalls so that part of the PAH fraction may get back into the clean gas. In order to keep the cleaning efficiency at a high level, a periodical cleaning of the tar coated parts is therefore necessary, the so called burn-out mode. In the burn-out mode, a separate burn-out fan sucks hot burning chamber gases down through the ceramics. The condensates, as well as included un-burnable particles, start to liquefy and to drop into the bottom discharge cone (drop-out mode). This condensed tar will include around 10% ash and other inert compounds. So most of the non-combustibles, dust and ash will be removed from the system. By further increasing the temperature up © Fig. 9: RTO during erection ALUMINIUM · 1-2/2008 51 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 10: RTO with collecting ductwork and prefilter to a maximum of 550°C, it is possible to gasify all condensed hydrocarbons. These gases have a high calorific value and they can therefore be re-used as a fuel in the burning chamber. For this purpose special tar burners are installed. The result is a clean surface of the heat exchange blocks (Fig. 7). In any case, an upward airflow design from the bottom of the ceramics up to the burning chamber should be avoided because this would only lead to a complete infiltration of the ceramic heat exchanger media. At very high tar loads in the flue gas, it becomes necessary to run the burnout mode continuously and independently from the normal three-chamber operation. In this special case a fourth chamber is added to the RTO (Fig. 5). This allows a normal three-chamber operation while there is always one chamber in burn-out mode. In order to reach the required low emission limits, the valves of a RTO are the most important parts. If they are not tight enough, the resulting leakage will allow some flue gases to pass directly to the clean gas duct without passing the burning chamber. For this difficult application the standard design of the valve system was adapted by LTB. Especially during the drop-out mode, condensates drop down Fig. 12: Layout with furnace 52 Fig. 11: LTB HF absorbers from the ceramic bed into the valve box. In order to avoid clogging of the valves, the complete valve-box has been re-designed (see Figs. 8 and 9). The valves have been placed outside the dropping area so as to keep them and the sealing clean. All dropping condensates are collected in the heated cone below, from where they can be discharged easily. However, normal ‘poppet’ valves or rotary systems would fail for technical design reasons, especially at the influence of high temperatures caused by the burn-out mode. As a final stage of the plant, a HF treatment system could be added (Fig. 12). As wet scrubbing systems would create waste water from this application, a dry packed bed scrubber is preferred. This technology was developed by LTB in the 1980s and is used in several installations of the ceramic industry (Fig. 11). Inside the casing there are several cascades, filled with grainy limestone. These absorption zones ensure a good contact of the HF with the absorbent, which will react spontaneously to fluoride (CaF2). References Experience and results In the experience of LTB, the RTObased type of flue gas cleaning is the only system which can reach the required low limits for volatile compounds under the hard conditions at baking furnaces. This experience is also used in green anode plants which run modified versions of the RTO. With the special carbon-design of the RTO, LTB achieved more than 97% cleaning efficiency for PAH and more than 98% related to benzo-a-pyrene, respectively. Nevertheless, the required PAH limits are quite low and hard to reach. Therefore additional, new methods of prefiltering and post-treating the clean gases are being tested to further reduce the emissions. The results will be presented later in a separate article. [1] Reference Document on Best Available Technology in the non ferrous metals industry, May 2000, European IPPC Bureau, Sevilla http://eippcb.irc.es. [2] M. Hagen: New requirements and solutions for the fume treatment at paste mixing and anode baking plants; Light Metals 2006, ed. T. J. Galloway (TMS, Warrendale, Pa), 615-619. [3] Procedair leaflet air pollution control 12/99. [4] W. Hammer et al.: UBA-FB AP 2058; Verminderung von PAH-Emissionen durch Errichtung und Betrieb einer thermischen Nachverbrennung mit Wärmerückgewinnung für Ringöfen zur Herstellung von Elektrographit; SGL Carbon GmbH; August 1994. [5] M. Hagen, W. Hilgert and R. Skiba: Results of operating a RTO based fume treatment system at a baking furnace; Light Metals 2007, ed. M. Sørlie (TMS, Warrendale, Pa), 977-980. Authors Dipl.- Ing. (FH) Matthias Hagen has been working for LTB for 20 years and is responsible for all sales. Dr.- Ing. Bernd Schricker at LTB is responsible for process design and new developments. ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U ALUMINIUM · 1-2/2008 53 I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 ALUMINIUM · 1-2/2008 53 A L U M I N I U M S M E LT I N G I N D U S T R Y New generation of FLSmidth Möller direct pot feeding system C. Duwe, Pinneberg; T. Letz, Dubai General description The secondary oxide (fluorinated alumina) from the gas treatment centres (GTC) is stored in silos near the GTC. This fluorinated alumina is then taken from the silos and transported di- rectly by the direct pot feeding system to each of the electrolytic cells. This transport system is pneumatic and it continuously feeds the fluorinated alumina to each of the electrolytic Fig. 1: Process flow diagram for the new generation of Möller cells. The direct direct pot feeding system pot feeding system works independently of the potroom centre and transported to the main cranes; it is fully automatic and abintermediate bins, normally one main solutely tight. This design minimises intermediate bin for each half of a pot maintenance work as well as the room. quantity of spare parts needed. More MF slide pipes transport the alumina to the main intermediate bins (near the potroom walls) as well Functional description as along the two potroom walls. The main MF pipe air slide DN 300 along The new generation of Möller direct the potroom feeds distribution bins. pot feeding (DPF) is no longer a dense Each of these bins feeds two electrolphase conveying system with pressure ysis cells via fluidflow super feeding vessel for the long distance transport system pipes DN 100. combined with super feeding system All necessary venting domes are pipe air slide for conveying to each connected with the gas duct. of the electrolytic cells. The new DPF The fluidflow DPF system works system consists of 100 percent Möller fully automatically and is more or fluidflow (MF) pipe air slides DN 100 less 100 percent filled with alumina – 300 to avoid scaling-effects, attrition all the time. (generation of fines) and segregation. The fluorinated alumina is taken Customers often have different refrom the silo at the gas treatment quirements as regards access to crust breakers and to dosing devices, and the options for removing alumina ore bunkers during potline operation. These requirements influence the final design of the MF super feeding system pipe DN 100 on top of the electrolyte cell. When the bunker of an electrolysis cell is full, the bulk material cone Fig. 2: Fluorinated alumina silo, Möller fluidflow (MF) pipe air slide to potroom wall, main intermediate bin, fluidflow pipe air slide along the potroom 54 Illustrations: FLSmidth Möller Aluminium has become more important for many industries and branches in the last 20 years. Primary aluminium is produced in so-called electrolytic cells in aluminium smelter potlines. In the past, large pot room cranes fed these electrolytic cells with the following disadvantages: • Non-continuous feeding of the electrolytic cells • Dust emission when refilling the alumina bunkers on the pots • Significant loss of alumina during filling • Considerable crane capacity needed • Extra man-power needed • Fluctuating electrolyte composition causes polluting anode effects • Anode effects reduce the efficiency of the smelting process • High investment and maintenance costs for the potroom cranes. Because of this, Möller developed a direct pot feeding system. Fig. 3: Möller distribution bin ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 • No generation of fine particles The self-closing filling • No segregation spout due to the mate• No scaling rial cone level in the ore • Lowest possible (over) pressure bunker of an electrolytic • No pressure-tight sealing of the cell allows a self-regulatelectrolyte cell ing and continuous re• Minimized energy consumption filling of the ore bunkers • Minimized maintenance work. during operation of the The fluidisation air for the MF pipe is smelting plant. The selfsupplied by rotary piston blowers. The closed filling spout and fluidisation air for the MF super feedthe filling process of the ing system on top of the electrolysis ore bunker are shown in Fig. 4: Various designs of MF super feeding system (SFS) pipe DN 100 on top of the electrolysis cell cells comes from frequency-controlFig. 6 (see next page). led rotary piston blowers in order to Furthermore, the sysreduce the energy consumption down tem needs no pressure-tight sealing of level blocks the filling spout discharge to that needed for the air actually © the electrolysis cell thanks to the low opening of the MF air slide pipe, and (over) pressure in the so the flow of alumina stops autoMF air slide pipe. matically. As fluorinated alumina is The main advanremoved from the ore bunker of the tages of the new genelectrolytic cell, the level drops and eration of MF direct pot the pneumatic transport starts again feeding system are: automatically, ensuring a constant • Self-regulating and and reliable mass feed rate to the pots. continuous feeding of Fluidising of the fluorinated alumina ore bunkers inside the MF air slide pipe works • Absolutely dust-free permanently to ensure a constant operation bulk density. Fig. 5: SFS pipe DN 100 on top of the electrolysis cell BUSS Anode Technology we engineer your plant! you at …see 008 TMS 2rleans New O 13 h 09 – from conceptual stage to realization Hohenrainstrasse 10; CH- 4133 Pratteln 1; Switzerland +41 (0) 618 256 462; [email protected]; www.buss-ct.com Marc 1 No. 63 Booth A L U M I N I U M S M E LT I N G I N D U S T R Y used. The technical design data and requirements for direct pot feeding systems tend to be very similar but vary depending on the local conditions. The data below are from a smelter plant in Siberia. Conclusion Fig. 6: Self-closed filling spout and filling process of the ore bunker Technical Data (example) Location of erection: Russia Altitude of plant location: 367 m above sea level Ambient temperature: min. -50°C, max. 36°C Conveyed material: Al2O3 (fluorinated alumina) Bulk density: 0.95 – 1,05 t/m3 Particle size distribution: 100% < 200 μm 90% < 125 μm up to 15% < 45 μm Material temperature: 30°C to 60°C Moisture content: < 0,5 weight % moisture content (during summer months < 0,6 weight %) Material characteristics: free flowing, not adhesive, fluidisable with 1-2 m3/min/m3 Number of potlines: 2 Number of potrooms: 4 Number of CAD units: 4 Number of cells: 672 (4 CAD with 168 cells) Design conveying capacity: 250 kg/h (each cell) Fluidisation air for 4 x 1 group of 3 blowers (2 duty, 1 stand-by) fluidflow: frequency controlled Fluidisation air for 4 x 1 group of 3 blowers (2 duty, 1 stand-by) SFS pipe air slides: frequency controlled The new generation of Möller fluidflow direct pot feeding system has been ordered for Dubai potline 6b (40 electrolysis cells), Hormozal Smelter (228 electrolyte cells) as well as for Taishet Smelter (672 electrolyte cells) and Boguchansky Smelter (672 electrolyte cells). This system is designed to ensure the most constant and reliable feed possible from the ore bunkers into the electrolysis cell. Lowest possible conveying velocities preserve the particle size distribution and the flow ability of the secondary alumina and so avoiding scaling effects. This most competitive system is superior also by minimizing wear and maintenance as well as energy consumption and last but not least by high operating reliability. The successful story of the company’s direct pot feeding will continue with this new technology, started at Hamburger Aluminium Werk in 1997 and at Aluminij Mostar in 2001. Authors Dipl.-Ing. Carsten Duwe is Head of Technical Department of FLSmidth Möller, based in Pinneberg, Germany. Dipl.-Ing. Timo Letz is Senior Engineer Sales and Project Department of FLSmidth Middle East, Dubai. Metal treatment update B. Maltais, D. Privé and M.-A. Thibault; Chicoutimi At the TMS annual conference in 2002, an interesting and timely paper (A Technical Perspective on Molten Aluminium Processing) was presented, in which the author described the quality requirements for aluminium and its alloys. In particular, he stated that only “step-wise improvements to quality / productivity / capacity are anticipated”. During the last six years following this presentation, there has indeed been a “step-wise” improvement in metal treatment. For example, once metal is siphoned from pots in the pot room, then the 56 prevention of potline bath carry-over is an ongoing battle. A new detection method was presented at the recent Australian Cast House Conference, in which the presence of bath is automatically signalled thus alerting the operators to take preventive action. Automated skimmers are being installed in many plants to ensure that any bath carry over is removed prior to transport to the casthouse or to the treatment of aluminium in crucible (TAC) station, for which several new designs have been recently implemented. TAC stations eliminate the need for sodium removal downstream in the cast house. More and more plants are turning to siphoning from the pot crucibles into the casting furnaces. This approach is particularly recommended when a new furnace is being installed so that the design criteria can be easily met. In older plants, there are often height limitations or restrictions for access into the furnace for the siphon tube. Siphoning reduces metal turbulence and hence minimizes dross generation. To meet the ongoing requirement to reduce chlorine gas in plants, the use of either manual additions of salts in the casting furnaces or automated rotary flux injectors was developed. ALUMINIUM · 1-2/2008 I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 Illustrations: STAS S AML S M E L T I N G A LPU E M ICN II U Fig. 1: TAC and automatic skimming unit It is now clearly demonstrated and well established that alkali and inclusion removal is possible without using chlorine gas. The salts used for this application contain magnesium and potassium chloride with compositions using less magnesium chloride yet attaining equivalent removal efficiencies. In a continuing effort to reduce chlorine usage, new procedures have shown that additions of chlorine to a limited number of rotors in a multi-stage degasser can be more effective in reducing inclusions. Moreover, chlorine usage can be completely eliminated from degassers when salt additions are made to optimize inclusion removal. Technologies for metal treatment Automatic skimming machine: Most producers in the past removed bath material manually, exposing the operators to safety and hygiene risks while still not efficiently removing bath. Now, automatic skimming machines are available on the market, adapted to specific customer needs, ALUMINIUM · 1-2/2008 57 Fig. 2: Efficiencies observed with use of TAC and to the particular transport modes in the plant. Many new designs now available are equipped with a tool especially designed to remove the maximum of solid bath and dross from the metal surface. In fact, the skimming efficiency of this machine can be up to 85 percent dross / bath removal on a consistent basis. Moreover, the automatic skimming machine does not require an operator. Treatment of aluminium in a crucible: The TAC technology injects of aluminium fluoride directly into the crucible to effectively remove the alkali and alkaline earth metals from molten aluminium without using chlorine gas. Prior to the TAC operation, the bath material has to be removed. An automatic skimming machine can be integrated with the TAC station to remove this bath material, and can also reduce labour costs and safety and hygiene problems. If required, the skimmer can be used again to remove dross after the TAC operation. The TAC technology can efficiently achieve a concentration of sodium after treatment as low as few ppm within a treatment time between 5 and 10 minutes, from an initial value over 100 ppm. One of the main advantages of the TAC is that the flux material (aluminium fluoride) is readily available in the smelter and it can be recycled to the pots when the crucible walls are cleaned with a crucible cleaning machine. Smelter grade AlF3 is suitable. Typically, 1 kg of flux per tonne of aluminium is used. Brief description of the equipment: Figure 1 shows an example of TAC installations in modern smelters. The rotation of the TAC agitator is powered by an electric motor coupled to a gearbox. The rotation speed is in the range of 100 to 200 rpm. The complete equipment and its installation are in accordance with EC standard to ensure a high level of safety for the operators. Advantages of the TAC-automatic skimming equipment: no chlorine is used; pot room crucible used; extremely rapid (less than 10 minutes); automatic, PLC operation; integrated dust collector system; low operating cost. © ALUMINIUM · 1-2/2008 57 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 3: Rotary injector Rotary fluxing technologies (e. g. RFI/ RGI): In several plants, furnace fluxing is still used to meet product requirements with respect to dissolved alkalis (lithium, sodium, calcium), non-metallic inclusions and hydrogen. Furnace fluxing has been traditionally done either manually with a salt mix or else using static lances with a mixture of chlorine / nitrogen gases. These processes have been progressively replaced by rotary injectors using chlorine gas (RGI) or salt mixtures (RFI). Alkalines are removed significantly faster with the RFI / RGI rotary equipment in comparison with lance fluxing. The RGI still uses a mixture of chlorine / nitrogen, but it uses much less chlorine than does conventional lance fluxing. On the other hand, the RFI completely replaces chlorine by salts containing magnesium and potassium chloride. Fig. 4: Alcan compact degasser Rotary salt fluxing processes help achieve high removal efficiencies within limited process times. However, the main gain is in terms of environment and safety issues. Brief description of the equipment: The injection module is composed of a graphite rotor and shaft, a driving system and a flux feeder. The flux feeder contains and doses the flux required for one treatment. The dosing system allows for the precise distribution of the flux during a treatment. The injection module must be placed at a very specific location into molten metal. Since each plant and even each furnace is different, several designs have been developed to meet customer requirements. Some equipment can be used to treat one furnace only, while others can treat two furnaces in sequence. Mobile units have also been developed to process several furnaces. Advantages of the RFI equipment: reduces alkalis, inclusions, HCl and dust emissions; ensures temperature and alloy homogeneity by stirring action; eliminates the use of chlorine gas for furnace fluxing. Degassing technologies (e. g. ACD): The aluminium compact degasser (ACD) is a multi-stage, in-line degassing machine that treats molten aluminium directly in the trough. Several papers have described this technology in the past ten years. Brief description of the equipment: The ACD is composed of three main components: • One or more driving modules: drive assembly for the graphite rotors used to inject and disperse the treatment gases (mixture of chlorine/argon or argon only) • A sealed hood: this supports the drive module(s), encloses the fumes generated during treatment, Fig. 5: Conventional versus sealed ACD 58 ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 and shields the metal from ambient conditions • A retraction system: lowers and raises the hood and maintains it at the position required for maintenance operations. Control is automatic through the use of a PLC. Advantages of the degassing technologies: removes alkalis and inclusions when chlorine is used; allows treatment with 2 to 8 rotor systems for metal flow rates from 20 up to 1,500 kg/min for the ACD; avoids loss of metal due to alloy changes for the ACD; avoids need to heat unit for the ACD; suits inline salt injection system. Technology comparison – conventional vs sealed ACD: In the recent years, the ACD has been improved to operate under sealed conditions (see Fig. 5 for design changes). Conventional unit: Conventional ACDs create forced air circulation through the interior of the hood. This mode of operation originally served to eliminate dross reactivity by (burning) after treatment of AlMg alloys. Sealed unit: The basic principle is to maintain the inside of the ACD hood under argon atmosphere to exclude oxygen as far as possible. For that purpose, the ACD hood has been completely redesigned. All means have been implemented to eliminate air infiltration. Benefits of sealed ACD: lowers dross generation; allows ACD operation without the use of chlorine; reduces emission of particulate matter. In-line salt feeding system: In-line salt injection involves adding of very small amounts of solid flux underneath the molten aluminium surface. This technology takes advantage of the strong shearing forces developed around the ACD rotor heads to properly disperse the liquid salt droplets. The solid flux assists alkali removal and inclusion removal using commercial fused or non-fused MgCl2/ KCl mixtures. This approach is an alternative for plants that want to avoid or eliminate gaseous chlorine injection in in-line degassers. The theory of alkali and inclusion removal from aluminium by using MgCl2/KCl mixtures is well described in the literature. Brief description of the equipment: The inline flux feeder takes advantage of the ACD rotor design to inject solid flux through the shaft central opening. The flux is then directly delivered inside the rotating disperser underneath the metal surface. Hence, the liquefied salt droplets are efficiently dispersed within the molten metal. This configuration, as for salt injection, is the key element for the © ALUMINIUM · 1-2/2008 59 59 A L U M I N I U M S M E LT I N G I N D U S T R Y efficiency of the ACD salt injection process. Thanks to its patented disperser design, the ACD is among the few technologies that can offer inline salt injection. A more detailed description can be found in the TMS article presented in 2007. Metallurgical performances with different configurations of ACDs To compare different configurations in various plants, metallurgical performance tests have been performed, the results of which are briefly presented below. The ACD configurations are: • ACD without chlorine • ACD with chlorine (original design, where chlorine is injected through all but one rotor) • ACD with chlorine (by limiting the number of rotors for chlorine injection) • ACD with salt injection (in replacement of chlorine). Hydrogen removal: The most important function of an ACD is to remove dissolved hydrogen from molten aluminium. It is worth mentioning that using the ACD for hydrogen removal is equivalent to using a box type degasser. Since the hydrogen escapes in bubbles of other gases, there is no difference between using the ACD argon with chlorine, without chlorine or even with the salt injection system. In fact, the results depend on the volume Fig. 6: Salt injection system 60 of gas injected, the efficiency of gas dispersion, and the residence time of the gas bubbles in the molten metal. Using the AlSCAN method to monitor the results, ACDs have shown similar degassing efficiency with or without chlorine. Results based on the latest improvement using an MgCl2 based salt to replace chlorine have shown equivalent removal performances in similar process conditions. Inclusion removal: Without use of chlorine: Over the last years, there has been a worldwide movement toward the elimination of chlorine from cast houses because of environmental, hygiene and safety concerns. Six years ago, only a few ACDs were operated without chlorine injection. Inclusion removal was characterised as inconsistent, to say the least. The dross generated inside the ACD was found to be much ‘wetter’ without chlorine than with it. In these conditions, the inclusions can be easily re-entrained into the melt, thus explaining the low or non existent inclusion removal. Nowadays, more than 20 ACDs of the latest sealed design are in operation using argon only. However, even with sealed ACDs, which generate and show no surface dross, inclusion removal efficiency is still inconsistent without chlorine. To achieve consistent inclusion removal, a modified agent is needed to make the inclusions less wettable, so that they stay separate at the aluminium surface. With use of chlorine: It is well documented that consistent inclusion removal efficiency through in-line degassing requires a minimum input of chlorine. From the first development of the ACD in the early 1990s, chlorine was injected underneath the metal surface through all the rotors but the last one, which injects argon only. The typical inclusion removal performance associated with a standard chlorine injection configuration may vary from 25 up to 60 percent. However, it is important to highlight that the higher the cleanliness of the metal coming from the furnace, the lower the proportion of inclusion removal will be. Recent plant experiments have shown that limiting the number of rotors that inject chlorine can help achieve higher and more consistent inclusion removal efficiencies (Fig. 7). Salt Injection: As published at the last TMS, inclusion removal is more efficient when salt is used instead of chlorine (Fig. 8). Alkali removal: Except for the configuration that uses argon only, alkali removal is equivalent for all other configurations (with chlorine or salt injection), with a removal efficiency of 40 to 60 percent. As a comparison, the performance obtained without injection of a chemically active reactant (argon only) are also included in the figure. Argon alone achieved a 20 percent efficiency of alkali removal since the turbulent mixing vaporizes sodium into the bubbles. Indeed, sodium’s high activity coefficient and vapour pressure favour it removal in the ACD. Conclusion To the authors’ knowledge, of a dozen customers who have installed or demonstrated a strong interest in the TAC over the six last years, most have coupled their machines with a skimming machine. The new automatic skimming machines remove bath more precisely than the manual method, and they avoid health and safety problems for the operators. It is worth noting that the use of the flux injection technology is more and more an option for smelters and recycling plants to treat liquid metal in furnaces. A lower magnesium chloride content in salt flux has proved as effective as a higher content. With the ACD, reducing the number of rotors injecting chlorine has given similar or even better results in terms of alkali or inclusion removal. ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 Finally, as presented at the TMS 2007, the new salt injection system offers an improved solution which completely eliminates chlorine gas from the cast house. Acknowledgement Sincere thanks are due to the Alcan’s personnel and the STAS design team, without whose dedication the success of this work would not have been possible. Authors Bruno Maltais, Dominique Privé and Marc-André Thibault are with STAS Inc., based in Chicoutimi, Canada. Fig. 7: Inclusion removal efficiency Fig. 8: Inclusion removal efficiency: in-line salt injection versus chlorine injection Fig. 9: Alkali removal efficiency: argon only, chlorine injection, salt injection Auto control system for quality casting J. Strömbeck, Hono This article explains how an existing casthouse can easily become a modern automated factory using Precimeter’s step-by-step process upgrade philosophy. The foundry industry has traditionally been regarded as a low tech, heavy and dangerous working environment. With the Precimeter ‘auto control system’ all this can change into a modern, clean and safe environment. Traditionally in casting, the metal flow has been manually controlled by an operator. Casting plants depend on their most experienced operators for high productivity and good quality. These professionals are getting harder ALUMINIUM · 1-2/2008 61 to find. If they are on sick leave, or replaced by someone less experienced, production suffers. Often, the control of metal flow into the mould depends on floaters. These devices are inaccurate since they can change over time as frozen metal adheres to them or they can malfunction due to mechanical friction and wear. The throttling device moves in direct proportion to the floater position, and disregards the characteristics of flow rate versus slider position. The level controlled is determined by the individual floater, and so cannot be changed during the cast. Also, floaters provide no inherent way of recording the metal levels using floaters. The Precimeter auto control sys- tem revolutionizes the whole casting process by offering step-by-step automation from a single metal level control to a fully automatic casting process. The system provides benefits including: • Improved quality due to steady metal levels throughout the process • Increased productivity since eliminating human error gives better recovery rates • Safer working environment for the operators • Casting repeatability • Documentation of the process • Step-by-step improvements • Flexibility in setting metal levels throughout the casting process • Better use of manpower. © ALUMINIUM · 1-2/2008 61 Illustrations: Precimeter A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 1: Stationary furnace controlled by TXP-6E tap-out actuator, ProH sensor and control system Fig. 2: Tilting furnace controlled by ProH sensor and control system Fig. 3: Control of molten metal level for rod casting with PXP-2E pin position actuator Fig. 4: Control of molten metal level in sheet casting with PXP-2E actuator 62 The concept of a fully automatic casting process can be implemented in existing casting processes. Using a step by step approach one can upgrade one part at a time. The normal approach to automating casting begins by analysing the current manual process and isolating the crucial elements to optimize the return on the initial investment. This could for example begin with automating the furnace control or the filling of the mould. The way to begin depends on what the customer regards as the key element to improve. Once installed, the auto control system is ready for the next level of automation just by adding the Precimeter components, which consist of the well known, market leading molten metal level sensor ProH together with a range of suitable actuators. Today, most furnace tapping processes are manually controlled. There are two main types of furnaces: tilting and stationary. The tilting furnace employs a hydraulic piston that slowly tilts the furnace to let the molten metal flow into the launder system. The tilting action is manually controlled using push buttons up / down. The operator looks at the level downstream and uses his experience to control the metal level in order to get a good flow of molten metal. The stationary (also called gravity) furnace has a low positioned tap hole which is opened to start casting. The operator adjusts the flow manually using a control rod to a cone in the tap hole. This is a dangerous operation where the operator is close to the molten metal; in addition, it is very difficult to estimate by eye and accurately control the level further downstream. The process obviously depends on an expert proficient with the process. Precimeter has, together with leading furnace manufacturers and aluminium foundries, studied and developed advanced, affordable solutions to automate these operations. The first priority for the stationary furnace has of course been the safety of the operator. The employer is responsible, and cannot ignore the risk to a man standing close to the furnace tap out hole for hours to adjust the control rod. Such working hazards must be avoided. New as well as old stationary furnaces can now be equipped with a tapout actuator TXP-6E or TXP-10. The actuator clamps onto the control rod with the cone, moving it in or out of the tap hole, so as to maintain the desired metal level in the launder. The actual metal level downstream is measured with the ProH digital camera sensor, which feeds a signal back to a closed loop auto control system, type MLC M1, controlling the tap-out actuator. This complete system (actuator, sensor and control unit) guarantees the desired metal level on set point within an accuracy of 0.5 mm. This is better than any human operator can achieve, and improves safety for the operators, who do not need to stand as close to the molten metal (Fig. 1). Accurate level control ensures quality casting by reducing variables to constants. A computerized control system is able to reliably repeat the same casting results over and over again. This means less scrap and less down time. A tilting furnace does not represent the same hazards for the employees as a stationary furnace. The control buttons can be placed further away from the molten metal, so the operator can be further from the danger zone. But the operator still has a great difficulty in keeping the same metal level during each cast and from cast to cast. This regulation depends on an experienced operator who estimates metal level by eye and tries to keep it constant only by manual adjustment. The solution to this problem is the new Precimeter system for tilting furnaces that uses a ProH sensor measuring the level downstream. When the operator decides that the level is perfect, he switches to automatic mode, and then the tilting of the furnace is controlled automatically; keeping the level on set point within 0.5 mm (Fig. 2). This system employs a ProH camera sensor and an auto control system MLC M1 as a very convenient retrofit kit. This leads to less scrap, less down time and better use of manpower as it frees up one operator from the duties of watching the metal levels. ALUMINIUM · 1-2/2008 S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 Moving one step further down in the process, there is obviously a need to control the metal levels in the mould. This is easily done with a flow control actuator and a ProH level sensor reading the metal level in the mould. The company has experience with casting installations, starting with controlling the mould and implementing the auto control system MLC M1 or A1, depending on how far the plant wants to automate. See figures 3 (rod), 4 (sheet) and 5 (ingot) as examples of different types of systems installed in production plants. The next natural step is to combine the furnace automation with the mould automation. This combined system is called ‘auto control flexible’, and it can handle up to 4 different levels in a casting process. It works with pre-programmed casting parameters and has an excellent repeatability. The system is easily handled through the operator interface, a touch screen. See figure 6 (billet casting) as an example. For a more advanced casting process control, the company offers the auto control system ‘MLC Advanced’. This system fully automates management of the entire casting process. Using this system has proved that it increases productivity and produces less rejects. The process can be recorded for traceability, and it learns to repeat the same top quality casting time after time. See figure 7 (slab) as an example. The company’s auto control systems can communicate with all major PLC brands used in factory automation worldwide; they can interconnect with any existing factory process control system to make the upgrade smooth. To provide safe and accurate function, all of the above systems use the ‘Smart Filter’ software developed and perfected by Precimeter’ software engineers during years of testing. The systems are being sold and installed worldwide by members of the company group and their representatives. These inventions take the industry a step forward by eliminating hazards, reducing scrap and rejects, improving quality, and utilizing manpower in a more efficient way. Author Fig. 5: Control of molten metal level in ingot casting with TXP-6E and starter dam actuators Jan Strömbeck, M. Sc., is Managing Director of Precimeter Control AB, based in Hono near Gothenburg in Sweden. Fig. 6: Billet casting with ProH sensor and Precimeter control system Fig. 7: Slab casting with PXP-2E and starter dam actuators ALUMINIUM · 1-2/2008 63 ALUMINIUM · 1-2/2008 63 A L U M I N I U M S M E LT I N G I N D U S T R Y History of intensive mixing for anode paste used in aluminium electrolysis About 84% of the world’s production of primary aluminium uses prebaked anodes: this amounted to approximately 30 million tonnes of the 35.5 million tonnes made in 2006. The remaining 5.5m tonnes came from older works with Soederberg technology so that the requirement for anode paste was about 16.5m tonnes for prebaked anodes and 3m tonnes for Soederberg. More than every second prebaked anode is produced from either completely (Eirich Mixing Cascade, ‘EMC’) or partially (cooler) intensively prepared paste. So, intensive mixers for anode paste have become state-of-the-art in the primary aluminium industry. Remixing and cooling of anode paste Already in the 1970s, individual intensive mixers were used as continuously operating coolers for anode paste e. g., in the Netherlands and in Bahrain, then an exten- tinuously operating Eirich intensive mixer proved it could not only cope reliably with cooling but could also achieve excellent homogenization of the paste. By directly adding water which immediately evaporates from the anode paste it achieves far higher cooling capacities than established systems have ever reached. On top of that is the effect of an almost ‘cost- Fig. 3: Development of baked density free’ homogenizer: the cooler also achieves a considerably • Hot mixing temperature improved paste quality compared to optimized (increased) since it single-step preparation thanks to the becomes independent of the relatively long retention time of 4 to forming temperature 5 minutes, the intensive mixing effect, • Long retention time and intensive and the additionally introduced mixremixing of the paste • Additional mixing energy ing energy of approximately 4 kWh/t. • Higher green and baked density This is why hardly any single-step and/or less pitch consumption paste preparation lines were built in • Lower electric resistance of the the last 15 years. In the same period, anode numerous existing plants were retro• Clearly reduced porosity and fitted with Eirich intensive remixeroptimized pore structure coolers. Integrating this additional • Lower chemical reactivity machine into an existing building • Allows some overall increase in often posed a great challenge for the the performance of the paste engineers. In the end, they always found a solution so as to profit from preparation. the decisive advantages. It is important to note that such plants have a greater construction height beThe advantages are: cause they need an efficient exhaust • Agglomerate-free paste with air treatment system to extract steam constant temperature and pitch fumes efficiently. • Essentially more stable paste The effect of the Eirich cooler bequality by reducing parameter comes especially apparent when retrovariations to less than 50% fitting into existing lines because here Fig. 1: Intensive mixing principle sive test series at the Pechiney works in Sabart (France) led to the breakthrough of this technology around 1990 with two more machines in France and Australia. At that time, the customer was looking for a paste cooler of high performance and efficiency. The con- 64 Fig. 2: Green paste porosity as an indicator of mixing efficiency ALUMINIUM · 1-2/2008 Illustrations: Eirich B. Hohl, Hardheim S AML S M E L T I N G A LPU E M ICN II U I N D U S TTRMYS & A L U M I N I U M I N D I A 2 0 0 8 tention time, compensation of short-time variations in paste composition, especially efficient and thus moderate energy input etc. On top of that the machines are also available for up to the highest throughput rates so that an anode plant with just one single preparation line can supply most modern smelters with more than 600,000 tpy of aluminium. EMC lines are available for throughputs from 10 t/h to more than 60 t/h. In recent years several lines were built in Europe, Africa and East Asia. In 2008, the first high-performance line with a throughput rate of 60 t/h will be supplied to an aluminium smelter at the Persian Gulf. Conclusion Fig. 4: Flow diagram EMC a direct comparison of preparation quality is easily to do. All-intensive preparation of anode paste The success of the intensive mixing principle for paste cooling led to the development of the EMC. Two seriesconnected intensive mixers perform first hot mix the coke and binding pitch and then subsequent remix and cool the paste. The operational advantages of the Eirich intensive mixer show up as low operating and maintenance costs, short standstill periods for any wear-related repairs, long re- Thanks to its decisive benefits, Eirich intensive mixing has already become proven technology in the anode paste preparation sector. Further technical and commercial growth is sure to follow. The future lies with continuous anode paste preparation thanks to their high efficiency at low investment and operating costs. References 1) P. Stokka, Green paste porosity as an indicator of mixing efficiency, Light Metals TMS 1997, pp. 565-568. 2) B. Hohl and L. Gocnik, Installation of an anode paste cooling system at Slovalco, Light Metals TMS 2002, pp. 583-586. 3) B. Hohl and You Lai Wang, Experience Report – Aostar – anode paste preparation by means of a continuously operated intensive mixing cascade, Light Metals TMS 2006, pp. 583-587. Author Fig. 5: RV24 EMC 35 t/h at Aostar China ALUMINIUM · 1-2/2008 65 Dipl.-Ing. Berthold Hohl is Product Manager Carbon Technology at Maschinenfabrik Gustav Eirich GmbH & Co KG, Hardheim, Germany. ALUMINIUM · 1-2/2008 65 MARKT UND TECHNIK Ebner Industrieofenbau Anspruchsvolle Anwendungen bei der Wärmebehandlung Demanding heat treatment applications B. Rieth, Meerbusch B. Rieth, Meerbusch Fotos: Ebner Ebner Industrieofenbau Luftaufnahme vom Ebner-Standort Leonding nahe Linz, Österreich Aerial view of Ebner site at Leonding near Linz, Austria Diversifizierung ist eine der Strategien, mit denen internationale Anlagenbaufirmen versuchen, durch eine Erweiterung ihres Portfolios Einbußen an Sachlieferungen auszugleichen, die sie durch frühere Zugeständnisse zu umfangreichen Lokalfertigungen in aufstrebenden Märkten wie China hinnehmen mussten. Dies gilt nicht für die österreichische Firma Ebner Industrieofenbau, die zu den weltweit renommierten Anbietern von Wärmebehandlungsanlagen zählt. Die Erfolgsfaktoren dieses Unternehmens sind Spezialisierung auf Hochtechnologie, Qualität aus eigenen Fertigungsbetrieben und stetige Produktentwicklung. Schmelz- und Gießöfen sowie konventionelle Erwärmungsanlagen im Strangpressbereich sucht man bei Ebner vergeblich. Stattdessen hat sich das Familienunternehmen im Laufe seiner 60-jährigen Geschichte auf andere Produktlinien für die Wärmebehandlung von Halbzeugen aus Stahl und NE-Metallen konzentriert und mit diesen eine führende Marktposition erreicht. Dieses sind: • Haubenöfen für Stahlbandbunde 66 sowie Stahldrahtbunde • Stahlbandvergüteanlagen • Bandglühofenanlagen für legierte und unlegierte Stahlbänder • Haubenöfen für Messingbandbunde sowie Messingdrahtbunde • Stoßöfen zum Homogenisieren und Anwärmen von AluminiumWalzbarren • Durchlaufglühöfen als Bandschwebeöfen zum kontinuierlichen Glühen von Bändern sowie Rollenherdöfen für Aluminiumplatten und -bleche • Kammer-Glühöfen für Aluminiumbunde in Einzel- oder Mehrfachbelegung. Der hohe technologische Anspruch der Wärmebehandlungsanlagen von Ebner drückt sich im gemeinsamen „Hicon“-Logo aus. Es steht für High Convection und bedeutet den Einsatz der von Ebner entwickelten Hochkonvektions-Technologie, die sich durch eine funktionsspezifische und verlustarme Umwälzung der Ofenatmosphäre, optimierten Medienfluss um die gesamte Charge sowie einen sehr geringen Energieverbrauch dank effizienter Isolierung und externer Rekuperatoren für jede Ofenzone auszeichnet. Diversification is one of the strategies with which international plant manufacturers seek, by extending their product range, to counteract the inroads made into specialist supply sectors affected by earlier concessions which encouraged local manufacture in developing markets such as China. This does not apply to the Austrian company Ebner Industrieofenbau, one of the most renowned suppliers of heat treatment equipment worldwide. The factors that shape the company’s success are specialisation in high technology, quality from its own production operations, and continual product development. Do not expect to get melting and casting furnaces and conventional heating units for the extrusion sector from Ebner. Over its 60-year history the family-owned firm has concentrated on other product lines for the heat treatment of steel and NF-metal semis, and has achieved a marketleading position with them. They include: • bell annealing furnaces for steel strip and wire coils • steel strip tempering units • strip annealing units for alloyed and unalloyed steel strips • bell annealing furnaces for brass strip and wire coils • pusher-type furnaces for homogenising and heating aluminium rolling ingots • continuous furnaces as floatertype units for the continuous annealing of strips, and roller hearth furnaces for aluminium plates and sheets • chamber furnaces for annealing aluminium coils individually or in batches. The high technological sophistication of Ebner heat treatment units is proclaimed by the trademark ‘Hicon’, ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY This stands for ‘High Convection’, denoting the use of the high-convection technology developed by Ebner which is characterised by functionspecific and low-loss circulation of the furnace atmosphere, optimised media flow around the whole charge, and very low energy consumption thanks to the effective insulation and external recuperators for each furnace zone. Orientation towards the aluminium industry Besides the Hicon/H2 annealing technique, which is preferably used for annealing steel strip coils in a pure hydrogen atmosphere under high convection conditions, Ebner has developed numerous technologies and designs for heat treatment units for the aluminium industry. Examples are: • an optimised slot nozzle system for pusher-type furnaces, which ensures rapid and uniform heating of the whole charge in the furnace • an air-flow-controlled carrier system, which supports an aluminium strip up to 8 mm thick in the floater-type strip furnace • optimised quenching technology for the quenching of plates, bars and sections in water after the roller hearth furnace. The key components important for a heat treatment unit, such as fan aggregates for circulating the furnace atmosphere, burners, radiation tubes and much more, were developed in the company’s own laboratory, are constantly being improved, and tested for operational reliability in long-term tests. They are of course produced in the company’s own workshops. With its own design department for the sectors of mechanical engineering, gas and regulation technology, electro-technology, automation and visualisation, Ebner can not only react more flexibly to customers’ wishes and ever-stricter customer standards, but also take advantage of every improvement and accumulated knowledge from the commissioning of furnace units for the design of new equipment. © ALUMINIUM · 1-2/2008 Ausrichtung auf die Aluminiumindustrie Neben der Hicon/H2-Glühtechnik, die vorzugsweise zum Glühen von Stahlbandbunden in reiner Wasserstoffatmosphäre unter Hochkonvektionsbedingungen eingesetzt wird, hat Ebner eine Vielzahl von Technologien und Konstruktionen für Wärmebehandlungsanlagen für die Aluminiumbranche entwickelt. Beispiele sind: • ein optimiertes Schlitzdüsensystem für Stoßöfen, das eine rasche und gleichmäßige Erwärmung der gesamten Charge im Ofen garantiert, • ein luftströmungsgesteuertes Tragesystem, das ein bis zu 8 mm dickes Aluminiumband im Schwebebandofen trägt • eine optimierte Quenchtechnologie zum Abschrecken von Platten, Stangen und Profilen im Wasser beim Rollenherdofen. Die für eine Wärmebehandlungsanlage wichtigen Schlüsselkomponenten wie Ventilatoraggregate zum Umwälzen der Ofenatmosphäre, Brenner, Strahlrohre und vieles mehr wurden im hauseigenen Labor entwickelt, permanent verbessert und in Langzeittests über Jahre auf ihre Betriebsicherheit geprüft. Gefertigt werden sie selbstverständlich in den eigenen Werken. Mit eigenen Konstruktionsabteilungen in den Bereichen Maschinenbau, Gas- und Regeltechnik, Elektrotechnik, Automatisierung und Visualisierung kann Ebner nicht nur auf Kundenwünsche und die immer strenger werdenden Kundenstandards flexibel reagieren, sondern bei Neukonstruktionen von Wärmebehandlungsanlagen auch rasch sämtliche Weiterentwicklungen und Erkenntnisse berücksichtigen, die bei den Inbetriebnahmen von Ofenanlagen gemacht wurden. Marktführer bei Stoßöfen Beispiel Stoßöfen für Walzbarren: Mit bisher 35 weltweit gebauten Anlagen in den letzten 20 Jahren gilt Ebner als Marktführer auf diesem Gebiet. Stoßöfen werden eingesetzt zum Homogenisieren und Anwärmen auf Walztemperatur von Walzbarren mit Gewichten bis zu 30 Tonnen und Abmessungen bis zu 8650 x 2200 x 650 mm. Kürzest mögliche Anwärmzeiten mit einer maximalen Temperaturdifferenz von 6o K über die gesamte Charge werden durch Anwendung der Hicon-Technologie erreicht. Neben zwei Stoßöfen, die im neuen Warmwalzwerk von Yantai Nanshan in China bereits in Betrieb genommen wurden, liefert Ebner nach China drei weitere für Asia Aluminium sowie zwei für das neue Qualitäts-Bandwalzwerk von Xiamen Xiashun. Auch in Russland kommen neue Stoßöfen von Ebner zum Einsatz, und zwar im Alcoa-Werk Samara. Große Erwartungen auf eine Belebung des nordamerikanischen Marktes knüpft Ebner an einen neuen Auftrag von Alcoa Rigid Packaging in Knoxville, Tennessee. Die © Industrieofenbau seit 1902 1 ' 2*%-&#'#-&-'%%,%% &&* ' */!' ' -' ' "", ' -"* ' ,(*,' ' /*.#*,%3*$*'+,, % (' 3% 0 #%)%,,"*&,('%#'3"(&)!",,)///)%,,"*& Aluminium 2008 in Essen, 23.–25. September, Halle 4, Stand 4C24 67 MARKT UND TECHNIK beiden Stoßöfen, die im Herbst 2008 in Betrieb gehen werden, können mit 48 Barren, das entspricht 1.200 Tonnen, beschickt werden. Sie sind damit die weltgrößten dieser Bauart. Nicht nur durch die verbesserte Qualität und die niedrigeren Wartungskosten, sondern vor allem auch durch die von Ebner garantierte hohe Energieausnutzung angesichts der enorm gestiegenen Energiepreise rechnet sich diese Investition für Alcoa innerhalb weniger Jahre. Vergüten von Aluminium-Platten und Blechen: Wärmebehandlung im Grenzbereich Der von der Luftfahrtindustrie ausgehende Investitionsboom für Plattenerzeugungsanlagen bescherte dem Unternehmen in der jüngeren Vergangenheit mehrere beachtenswerte Aufträge. Die hierfür eingesetzten Rollenherdöfen nutzen neben der HiconTechnologie eine ebenfalls im Labor von Ebner entwickelte Quenchtechnologie, die auch die erforderliche Trocknung einschließt. Da es sich bei den Endprodukten zumeist um Platten und Bleche für die Luft- und Raumfahrt handelt, werden die Anlagen nach der strengen Luftfahrtnorm AMS 2750 D ausgelegt. Diese fordert, dass die Temperatur im Ofen (furnace class 1) während der Haltezeit an den beiden Grenztemperaturen nur um +/- 3o K abweicht. Vor kurzem in Betrieb genommen wurden die Rollenherdöfen für OAO KUMZ in Kamensk Uralski sowie für Alcoa OAO in Belaja Kalitva, beide in Russland. Die Plattendicken betragen 11 bis 150 mm bei einer beheizten Ofenlänge von 31,5 m bzw. 6 bis 200 mm bei 36 m beheizter Ofenlänge. Auch westeuropäische Werke haben sich für Rollenherdöfen von Ebner entschieden. Amag rolling GmbH in Österreich erhielt eine weitere Anlage für Plattendicken von 15 bis 100 mm bei einer beheizten Ofenlänge von 9,9 m, mit der Möglichkeit, die Anlage um eine weitere Zone zu verlängern. Für Aleris in Duffel, Belgien, wurde eine Anlage für Plattendicken von 3 bis 150 mm bei einer beheizten Ofenlänge von 19,8 m in Betrieb genommen. Das Ergebnis in all diesen 68 Fällen: bestmögliche Planheit, beMarket leader for schädigungsfreie Oberflächen und pusher-type furnaces einwandfreie Gefügestrukturen der vergüteten Platten. Consider the example of pusher-type Gerade auf dem Gebiet der Wärmefurnaces for rolling ingots: with 35 behandlung von Aluminiumplatten units built all over the world over konnte Ebner duch die Forschungsthe past 20 years, Ebner is the marmöglichkeiten im betriebseigenen ket leader in this field. Pusher-type Großlabor einen wichtigen Beitrag furnaces are used for homogenising zur Produkt- und Produktionsverand heating rolling ingots weighing besserung liefern. Durch die innovaup to 30 tonnes and measuring up to tiven Maßnahmen der F&E-Abteilung 8650 x 2200 x 650 mm, to their rollkonnten in enger Zusammenarbeit ing temperature. The shortest posmit den Anwendern völlig neu entsible heating times with a maximum wickelte Konzepte realisiert werden, temperature difference of 6°K over die auf modernste Qualitäts- und Leisthe whole charge are achieved by tungsanforderungen von Hightechthe application of Hicon technology. Produzenten und deren Produkte Besides two pusher-type furnaces alzugeschnitten sind. ready commissioned at the new rollIn diesem Zusammenhang meldet ing plant of Yantai Nanshan in China, Ebner die erstmalige Lieferung einer Ebner is also to deliver three more to Rollenherdofenanlage: nicht, wie bisChina for Asia Aluminium and two for her üblich, zur Wärmebehandlung the new high-grade strip rolling plant von Aluminiumplatten, sondern von of Xiamen Xiashun. In Russia too new Profilen aus Aluminiumlegierungen. pusher-type furnaces by Ebner are in Die für Aleris in Duffel bestimmte use, in particular at Alcoa in the SaAnlage ist für die über den gesamten mara works. Querschnitt verzugfreie WärmebeHigh expectations for the revival of handlung von komplexen Strangpressthe North American market are linked profilen mit maximalen Außenmaßen by Ebner to a new contract from Alcoa 250 x 560 mm und einer Länge von Rigid Packaging in Knoxville, Tennes13 m vorgesehen, die im Fahrzeug- und Flugzeugbau zur Anwendung kommen. Dieser Ofen stellt eine echte Innovation dar, bei deren Realisierung das Labor von Ebner in enger Zusammenar- Rollenherdofenanlage bei der AMAG rolling GmbH in Österreich beit mit dem Roller hearth furnace unit at AMAG rolling GmbH, Austria Kunden seine weitreichenden Möglichkeiten einsee. The two furnaces which will begin bringen konnte. Die bisherige vertioperating in autumn 2008 can take up kale Ofenbauweise mit all ihren Einto 48 ingots, corresponding to 1,200 schränkungen wird hier durch eine tonnes, and are therefore the largest of Horizontalanlage ersetzt. their type in the world. Alcoa expects a pay-back time of only a few years for this investment, not only because Kammeröfen mit Rechenmodell of improved quality and lower mainfür optimalen Glühzyklus tenance costs, but above all because of Ebner’s guarantee of high energy Auch bei dieser Produktlinie sucht efficiency set against the enormously Ebner die Marktnische von technoloincreased energy prices. gisch anspruchsvollen Anwendungen, ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY The investment boom in plate production plants created by the aviation industry has in the recent past secured a number of notable orders for Ebner. Besides Hicon technology the roller hearth furnaces used for this employ quenching technology also developed in the company’s laboratories, which also includes the necessary drying. Since the end products are mostly plates and sheets for use in aerospace, the plant is designed in accordance with the strict AMS 2750 D aviation standard, which demands that in a Class 1 furnace the temperature may only deviate at the two limit values by no ore than ± 3°K. Recently commissioned were the roller hearth furnaces for OAO KUMZ in Kamensk Uralski and Alcoa OAO in Belaja Kalitva, both in Russia. © PROFHAL entwickelt, fertigt und veredelt hochwertige Aluminium-Profil-SystemKomponenten für unterschiedlichste Anwendungsgebiete. INDIVIDUELLE LÖSUNGEN AUS ALUMINIUM ALUMINIUM · 1-2/2008 bei denen in zunehmendem Maße die Luftfahrtnormen zur Anwendung kommen. Dazu zählen auch die an Aleris Koblenz gelieferten Kammeröfen zum Glühen und Altern von Platten für die Flugzeugindustrie, wobei die zuletzt gelieferte Anlage für zukünftige Plattenlängen von 34 m und eine maximale Charge von 150 Tonnen bezüglich der geforderten Temperaturgleichmäßigkeit hervorzuheben ist, die weit unterhalb der von der Luftfahrt bisher geforderten Toleranzen liegt. Die bei Ebner im Laufe der Jahre über viele Versuchsreihen angelegten Datenbanken über Temperaturverläufe bei den unterschiedlichen Aluminiumlegierungen sind die Basis für eine Spitzenpositionierung bei der Entwicklung von Rechenmodellen. Übertragen auf die Produktionsanlagen steuern sie mit hoher Zuverlässigkeit die Temperaturführung während des gesamten Wärmebehandlungsvorgangs. Erwähnenswert ist in die- sem Zusammenhang der Einsatz des von Ebner für Einzelbundöfen entwickelten Rechenmodells „BOS“ (Batch Furnace Optimization System), das erstmals auch bei einem MehrbundKammerofen angewendet wurde. Das Rechenmodell ermittelt für die jeweiligen Bunddimensionen und Legierungen sowie deren Glühparameter den optimalen Glühzyklus. Die vorausberechneten Temperatur- und Zeitwerte werden laufend mit den gemessenen Werten kontrolliert und bei Bedarf angepasst. Dies garantiert optimale metallurgische Eigenschaften und eine Reduktion der Durchlaufund somit der Produktionszeit. 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. www.haarmann-gruppe.de Tempering of aluminium plates and sheets: heat treatment in the limiting range PROFHAL ALUMINIUM PROFIL BEARBEITUNG GMBH Ein Unternehmen der HAARMANN-GRUPPE Dettenheimer Straße 30 91781 Weißenburg Tel. 0 91 41/8 55 65-0 www.profhal.de 69 MARKETS AND TECHNOLOGY truded sections plate lengths of 34 m and a maximum with maximum charge of 150 tonnes achieves results overall dimenfar below the tolerances demanded sions of 250 x for aviation until now. 560 mm and The database compiled by Ebner a length of 13 over the years on temperature variam, all over the tions in the various aluminium alloys, cross-section which are the fruit of numerous test without any series, are the basis for achieving a distortion or peak position in the development of warping. These computed models. When transferred are intended for to the production units these ensure use in automovery reliable control of the temperative and aircraft ture management throughout the heat engineering. treatment process. In this connection The furnace is it is worth mentioning Ebner’s use Stoßofenanlage bei Yantai Nanshan Aluminium in China a real innovaof the computed model ‘BOS’ (Batch Pusher-type furnace unit at Yantai Nanshan Aluminium, China tion, for whose Furnace Optimisation System) derealisation the Ebner laboratory colveloped by the company itself for The plate thicknesses range from 11 laborated closely with the customer single-coil furnaces, which was for to 150 mm in a furnace with a hot zone by providing its far-reaching posthe first time used also for a multi31.5 m in length, or 6 to 200 mm in sibilities. The previous, vertical furcoil chamber furnace. The computer one with a hot zone 36 m long, renace structure with all its limitations model determines the optimum anspectively. Plants in western Europe is in this case replaced by a horizontal nealing cycle for the coil dimensions too have opted for roller hearth furunit. and alloy concerned, and the annealnaces by Ebner. Amag rolling GmbH ing parameters required. The pre-calin Austria is getting another unit for culated temperature and time values plate thicknesses of 15 to 100 mm in Chamber furnaces with a are continuously checked against the a furnace hot zone 9.9 m long, with the computed model for measured values and adaptations are possibility of extending the unit by an optimal annealing cycles made as necessary. This ensures opadditional zone. For Aleris in Duffel, timum metallurgical properties and Belgium, a unit for plate thicknesses In this product line too Ebner has speeds up the throughput and hence of 3 to 150 mm in a furnace hot zone sought to serve the market niche of the production time. 19.8 m long has begun operating. The technologically sophisticated appliresult in all these cases has been the cations, for which the aviation standbest possible flatness, surfaces free ards are applied to an ever-increasfrom damage, and perfect metallurgiing extent. These also include the Author cal structures in the tempered plates. chamber furnaces supplied to Aleris Dipl.-Ing. Bernhard Rieth is a marketing Precisely in the field of aluminKoblenz for annealing and ageing specialist and freelance technical journalium plate heat treatment and thanks plates for the aircraft industry. In reist. As proprietor of Marketing Xpertise to the research facilities in its own lation to the temperature uniformity Rieth in Meerbusch he advises equipment major laboratory, Ebner has been demanded, it should be stressed that partners of the NF-metal semis industry on able to make important contributions the unit recently delivered for future marketing-related issues. towards product and production improvement. Thanks to the innovative Ebner Industrieofenbau – facts & figures activities of its R & D department and Founding year 1948 in close collaboration with customers, Main product lines Bell annealing furnaces, strip annealing furnaces, completely new concepts have been pusher-type furnaces, floater-type furnaces, roller hearth furnaces, chamber furnaces developed which are tailor-made for Total turnover 150 million euros the most modern quality and performManufacturing locations Employment ance demands made by high-tech Linz, Austria 750 manufacturers and their products. Wadsworth, Ohio/USA 60 In this connection Ebner has anTaicang, P.R. China 120 nounced the first delivery of a roller Additional service stations Japan, Taiwan hearth furnace unit, not as previously Industries served Turnover in percent usual for the heat treatment of aluminSteel 70% Aluminium 25% ium plates, but instead for that of aluCopper & Cu-alloys 5% minium alloy sections. The plant, desAnnual R & D expenditure At present: 5 to 6 percent of turnover tined for Aleris in Duffel, is designed In future: 8 percent of turnover for the heat treatment of complex ex- 70 ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY Peter H. Ebner: “The decisive factor for our success is the high quality standards we insist upon” Robert Ebner: “In the coming years we intend to increase our research and development expenditure to eight percent of turnover” “We decide the competition in terms of quality” Interview with Peter H. Ebner and Robert Ebner, CEO of Ebner Industrieofenbau GmbH ALUMINIUM: Mr. Ebner, for products such as Hicon / H2 bell annealing furnaces your company has developed to become the undisputed world market leader, and for other furnace types you are one of the top suppliers. To what do you attribute your outstanding position among international furnace manufacturers? Peter Ebner: The decisive factor for our success is the high quality standards we insist upon, and from which we will not deviate at any price. Even if we occasionally miss the mark and do not get a chance. Ebner’s focus is ALUMINIUM · 1-2/2008 the customer and his special technical requirements. Our aim is to offer him the technically optimum solution for his needs. ALUMINIUM: With no thought of price in this? P. Ebner: We are aware that our prices are at or near the top of the range. We cannot and do not wish to win orders by aggressive price competition. Rather, we look to establish a fair partnership with our customers, to whom we offer tailor-made plant solutions which work absolutely reliably for a long time. That cannot be done for bargain prices. When one looks not just purely at the purchase price of a unit but also at its long-term economy, we have no reason to fear competition from elsewhere. ALUMINIUM: Let us focus on the economic aspect. What are your main thoughts about that where a furnace is concerned? Robert Ebner: An essential criterion which is becoming continually more important is the energy-efficiency of our furnaces. I refer here to our Hicon technology, with which we equip all our furnaces. For example, at present we are building two pusher-type furnaces for our long-term customer Alcoa in the USA – in fact, the largest of their kind built anywhere in the world. Thanks to the substantially more efficient use of energy that is possible today compared with existing box furnaces, and also to their low maintenance needs, the customer’s pay-back time on the investment will amount to only a few years. ALUMINIUM: How much importance do you attach to the international orientation of your company with its facilities in Austria, the USA and China? P. Ebner: Ebner was founded in Linz sixty years ago by my father. That is still the headquarters and technical centre for our company’s know-how. Our American plant in Wadsworth, Ohio, was established in 1987. Our aim was to gain a foothold in the dollar area. From Wadsworth we serve the North American market and the regions that operate with US dollars. For Ebner, business in America grew rapidly until 1999. In the USA we sometimes even achieved a turnover fraction of almost fifty percent of all our business. ALUMINIUM: How is that plant justified today in view of the investment slump of the steel and NF industries there, which has lasted for some years? P. Ebner: Even through hard times I have continued believing in our commitment in America. Without a presence in the dollar area the region cannot be served, as is shown all too clearly now by the present weakness of the dollar. ALUMINIUM: So will you continue operating in America? R. Ebner: Of course. In the USA there are many furnaces which have been operating since the late forties or early fifties and which, in view of the high cost of energy, must now be replaced by modern, energy-saving units. ALUMINIUM: Let us now look at the most dynamic economic area of all: how do you assess development in Asia? P. Ebner: Our Asian business has been growing bit by bit for many years, and we have approached that market in small, well-prepared steps. After initially gaining a presence with servicing stations in Japan and Taiwan, it became increasingly clear as the years passed that we needed a production base of our own in Asia. R. Ebner: To begin with, we looked for suitable locations in South Korea. It is true that Korea would have had the necessary infrastructure, but it was very expensive. Thailand would have been suitable in terms of living conditions for our Austrian employees, but there the environment was not right. At the end of the day we opted for China. We had many preliminary talks to clarify location-related questions such as: what are the stumbling blocks, where is there an appropriate industrial estate, etc. Finally, in 2002 we decided to build a plant of our own in Taicang, near Shanghai, where we recently completed the fourth expansion stage. ALUMINIUM: How free were you in your decision-making? P. Ebner: What we built up in Taicang was created without any restrictions on the part of Chinese authorities. In any case it is not a joint © 71 MARKETS AND TECHNOLOGY venture, but a company wholly owned by Ebner. I would not have gone to China if it had been necessary to set up a joint venture there with a Chinese partner. ALUMINIUM: What experiences can you pass on to others who are faced with similar decisions? P. Ebner: Our USA project taught us that we could not rely purely on American staff, but that at least for some years we had to send across highly qualified technical personnel from Linz. Precisely for a company such as Ebner which sets great store by quality, that is unavoidable. The commitment of technicians from Linz on the basis of three- to five-year contracts was decisive in ensuring that both qualitatively and in terms of production figures, the plant attained satisfactory levels within two years. R. Ebner: The learning curve we travelled in the USA in our first years there, we could then avoid in China. From the beginning, the new production management and quality monitoring were in the hands of senior staff from our parent plant in Austria. Of course, that is not to belittle the importance of our Chinese employees, who have to deal with ‘China-internal’ issues. ALUMINIUM: It must surely have been an enormous challenge for a medium-sized company to do without some of its specialists at the parent plant. P. Ebner: Quite right, but there was no other way to guarantee our high quality standards – which for us, is indispensable. ALUMINIUM: Do you perceive signs that India’s steel and NF-metal industries will soon be following in China’s footsteps and so catching up? R. Ebner: In our estimation China has moved far ahead of India in terms of infrastructure and the quality of life of 72 personnel in recent years. It is true that India has the major advantage of using the English language, but the progress of its infrastructure is slow. Nevertheless, India is a very important growth market with a steadily expanding middle class, with many ‘consumers’, who stimulate the economy. India is becoming continually more important for us Europeans, but its development will not be as rapid as in China. P. Ebner: To return to our plant in China: we are naturally very interested in exporting from Taicang to the surrounding Asian countries, including India for at least the past year, where we are at present carrying out some major assembly projects. We provide the less expensive parts of furnaces Ebner laboratory at Leonding from Taicang – at prices that are very acceptable in India. ALUMINIUM: That raises the question: what do you now still produce in Linz? P. Ebner: Here in Linz we make all the components that are quality-critical for our business and which, if they were to be copied, would threaten the future of our company. Thus, so long as there is still no effective copyright or patent law in China, we will supply such know-how-rich components from Linz. ALUMINIUM: So how do you divide the production between your three plants? R. Ebner: We have analysed our various furnace types and split them into A-, B- and C-components. A-compo- nents are made only in Austria or the USA, B-components at all three locations, while because of labour costs it makes sense to produce C-components only in China. In the 1990s we resisted pressure from several customers who wanted us to produce key-components of our units – for example the bases of our bell annealing furnaces – in China as well. We strictly refused to do that, even at the risk of no longer receiving any orders. This led to four or five relatively slack years when we got fewer orders for bell annealing furnaces, until finally things changed again. Today, it is more of a selling-point for our furnaces that the core of our units come from Linz or the USA. ALUMINIUM: What other functions have you concentrated in Linz? R. Ebner: Our company philosophy is to do all the research in our laboratory in Austria, because the experience from all our plants comes together here and we do not want to operate a two-track system. Whether in good years or bad, we invest five to six percent of turnover in research and development. That is already a high proportion and in the coming years we even intend to increase it to eight percent. We are convinced that to secure the future of our company this is vitally important. Among other things we want to enlarge our laboratory. ALUMINIUM: What are the laboratory’s main tasks? P. Ebner: Consider for example the support of sales: quite often a customer comes to us because he cannot achieve the necessary product quality with his existing equipment. Nobody who comes to Ebner has to base his purchasing decisions on written guarantee values alone. Instead, we can demonstrate the quality guarantee we give using our own equipment. ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY For this, as a rule we work with test equipment on a one-to-ten scale and occasionally, for certain problems, with full-size units – for example the annealing of coil batches. We fit these with thermocouples all over, anneal and heat treat them in the presence of the customer, and he can then inspect the analyses himself or send them on to his own buyer. It is important that in our research we tend to and optimise the dovetailing and interplay of all the individual plant components. For example, we have long been developing our own burner technology because we do not want to rely on others for important plant components. ALUMINIUM: Has the development potential for furnaces not now been largely exhausted? R. Ebner: I do not believe so. As an example: in the case of bell annealing furnaces for steel coils, which with their hydrogen technology and high convection we have been selling very successfully for some thirty years, we have meanwhile arrived at the sixth generation. In this, we have boosted furnace performance by forty to fifty percent, whereas the price has moved downwards. Such development can only be achieved with a laboratory of one’s own. P. Ebner: Another thing that must not be underestimated: to help us remain an attractive employer the laboratory is a very important factor. That is where the technical staff can try out their own ideas, and this has so often been to our benefit, while in the meantime we have formed an international thirty-man team. ALUMINIUM: So the laboratory plays a major part among the factors that contribute to your success … P. Ebner: … as also does the low fluctuation level of our employment structure. We have people who already represent the third generation that has worked for Ebner. They often come to us as apprentices and stay on at Ebner all their working life. Every year we train twenty apprentices, and we have also adopted in America the same apprentice training as in Linz. We also offer our most able employees the chance to attend engineering college in the evenings and become more highly trained. We then place such employees in the laboratory, the design and construction departments, or in sales. ALUMINIUM: Mr. Peter and Mr. Robert Ebner, many thanks for this discussion. Siemens liefert Fertigstraße für Aluminium-Warmwalzwerk nach China Siemens Metals Technologies hat von der Chinalco Aluminium den Auftrag über die mechanische und elektrische Ausrüstung einer neuen Fertigstraße mit Zwillingshaspel erhalten. Das Warmwalzwerk wird bei der Chinalco Ruimin in Mawei/Fuzhou, Provinz Fukien, errichtet. Das Auftragsvolumen beträgt rund 20 Mio. Euro. Das erste Aluminiumband soll im September 2009 gewalzt werden. Die Fertigstraße ist Teil eines geplanten neuen Warmwalzwerkes, das im Zuge eines großangelegten Ausbauprojekts von Chinalco Ruimin in den nächsten Jahren errichtet werden soll. Das Vorgerüst und der vertikale Staucher werden von einem lokalen Lieferanten mit technischer Unterstützung von Siemens beigestellt. Die zu liefernde Fertigstraße umfasst ein Quarto-Gerüst mit automatischer hydraulischer Walzspaltregelung sowie positiver und negativer Arbeitswalzenbiegung. Das Warmwalzwerk wird über eine Kapazität von 270.000 Jahrestonnen verfügen und ist für Bänder mit Breiten © ALUMINIUM · 1-2/2008 Siemens supplies new aluminum hot finishing mill to China Siemens Metals Technologies has received an order from Chinalco Aluminium Co., Ltd, to supply the mechanical and electrical equipment for a new hot aluminium twin coiling finishing mill. The plant will be built at Chinalco Ruimin at Mawei/Fuzhou in Fujian province. The order volume is around 20 million euros; production of the first coil is scheduled for September 2009. This mill will form a key part of a proposed new aluminium 1+1 hot line, which is the key process component of a major plant expansion planned by Ruimin. The roughing stand and the vertical edger will be built by a local supplier with technical support by Siemens. The finishing mill will comprise a 4-high stand equipped with hydraulic automatic gauge control and positive and negative bending. The mill itself will be designed to roll a wide range of products and alloys, and will be capable of rolling over 270,000 tonnes per year at widths in excess of 2.2 metres. In addition to the mechanical equipment, Siemens is also supplying the entire automation system and the drive systems as well as the process automation system for the complete hot line. All the components and systems used are part of ‘Siroll Alu’, the integrated solution for aluminium hot mills. UK facilities become Competence Centre for plate rolling mills and aluminium plants Siemens Metals Technologies has combined its two UK locations in Sheffield and Christchurch into the special subdivision ‘Plate & Aluminium Rolling’, which will be responsible for the worldwide business © 73 MARKT UND TECHNIK von mehr als 2,2 Meter ausgelegt. Neben der mechanischen Ausrüstung liefert Siemens das komplette Automatisierungssystem und die Antriebstechnik, außerdem die Prozessautomatisierung für das gesamte Warmwalzwerk. Alle eingesetzten Systeme und Komponenten sind Bestandteil von „Siroll Alu“, der integrierten Lösungsplattform vom Siemens für Aluminium-Warmwalzwerke. Britischer Standort wird Kompetenzcenter für Grobblech-Walzstraßen und Aluminiumanlagen Siemens Metals Technologies hat seine beiden britischen Standorte Sheffield und Christchurch zu dem Geschäftszweig „Plate and Aluminium Rolling” zusammengefasst, in dem künftig das weltweite Geschäft mit Grobblech- und Aluminiumwalzstraßen betrieben wird. Der steigende Bedarf an Grobblechen beflügele auch das Anlagengeschäft mit Walzstraßen, sagte Hans-Werner Linne, Leiter des neuen Geschäftszweiges. Während vor allem in China, Indien und Russland der Neubau von Anlagen geplant wird, liegt der Schwerpunkt in Europa und Nordamerika auf der Modernisierung, um durch die Leistungssteigerung bestehender Anlagen die wachsende Nachfrage zu befriedigen. Dies lässt sich jedoch nur mit dem Ausbau des Serviceangebots erreichen. Um das Angebot zu erweitern, wurde daher die Plate Mill Consulting Group in Sheffield gegründet. Im Modernisierungsgeschäft verfügt der neue Geschäftszweig Siemens zufolge weltweit über einen Marktanteil von 48 Prozent bei Aluminiumanlagen. Schon heute, in einer Zeit boomender Neuanlagen-Projekte, will sich Siemens mit dieser Strategie auf neue Marktgegebenheiten künftiger Jahre vorbereiten. „Mittelfristig erwarten wir einen starken Anstieg des Modernisierungsgeschäftes”, so Linne. N with plate and aluminium rolling mills. The growing demand for heavy plate was also boosting project business with rolling mills, Hans-Werner Linne, head of the new subdivision, said. There are plans to construct new plants, especially in China, India and Russia, whereas, in Europe and North America, the focus is on modernisation. Here, improving the performance of existing plants is supposed to satisfy rising demand. This will involve expansion in the scope of maintenance solutions on offer as well as a wider range of services for plant modernisation. To this end, a Plate Mill Consulting Group was set up in Sheffield. According to Siemens the new business unit has global shares of 48% in modernising of aluminium mills. The task of the company is to take action in a time of booming ‘greenfield’ projects in order to adequately prepare for the market in the future. N Aluminium for building and construction in China Shi Lili, Beijing All sources: Beijing Antaike Chinas’s aluminium extrusion industry for building and construction took its first steps in 1980. In the 1990s China’s aluminium industry for building and construction moved into a new era featured by quality, variety, profits and product structure. Today China’s construction industry is the driving force of the growing demand for aluminium products. In the long run aluminium products for construction will maintain the leading position in the aluminium extrusion industry. Brief history and status quo Although China had its own complete aluminium products extrusion line as early as 1956 when Northeast Light Alloys Company was set up, and also brought over eight hydraulic machines from Japan UBE Machinery in 1971, these units were all devoted 74 to aluminium products for industrial use. China’s aluminium extrusion industry for building and construction took its first steps in March 1980 when Guangzhou Dongjiao Yuncun Aluminium 6th Plant was put into production. This was a joint venture be- tween Guangzhou 2nd Light Industry Aluminium Products Company and China Aluminium Corporation, Hong Kong. Except for a melting furnace and the anodic oxidation treatment line, all other technologies depended on Hong Kong and Taiwan. Also in ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY the same year, Liaoning Yingkou Aluminium Products Plant and Tianjin Aluminium Alloy Plant introduced 16.3 MN hydraulic machines from Japan UBE Machinery. This means that China’s aluminium production for building and construction started in both Northern and Southern regions almost at the same time. In the middle of the 1980s China was undergoing its first boom of the aluminium extrusion industry. By 1986 China had 175 aluminium extrusion plants with 380 kt/a of production capacity and 400 extrusion machines. However, a cold snap followed since the country adopted policies to restrict aluminium products and application in building and construction that year and aluminium production accordingly dropped substantially. Yet another surge of aluminium products in China began from 1991 to 1998 with deeper and more widespread influence than that of the mid 1980s. All provinces except for Tibet had their own extrusion plants, including five in Hainan Province in the far south of China. There were 1,142 plants in total with 4,000 extrusion machines and a total production capacity of 4,300 kt/a of at that time. Since then, China’s aluminium industry for building and construction has moderated the pursuit of quantity and moved into a new era featured by quality, variety, profits and product structure. After years of booming development since 1999, the number of extrusion plants dropped below 600 and all five of the plants in Hainan were shut down, mainly because of increasingly intense competition among the market participants and aggravating market conditions. After 2000, China began to shift its strategy and put more effort into the added value of aluminium products. Thus, production capacity increased at a lower rate of approximately 10 percent annually. By the end of 2005 the number of aluminium extrusion plants had fallen to 650, with approximately 5,100 kt/a of production capacity and 3,000 extrusion machines, and China held first place in terms of number of companies, production capacity and total production. ALUMINIUM · 1-2/2008 After years of adjustment of the product structure by the market, the number of extrusion plants has been on the decrease in recent years, yet total exports have gone up. In 2006 alone total exports amounted to 68 kt or 45 percent of total world exports, making China the major aluminium production base in the world. By the end of 2006 China’s aluminium extrusion production reached 4,500 kt/a, of which 80 percent was for building and construction. Advanced technologies and machines contributed a lot to this speedy development. At present, many Chinese extrusion companies have invested in foreign equipment and technologies which helped Chinese enterprises, both state owned and private, to make fast progress. This also brought huge 379 for coloured anodising, 86 for static spraying, 22 for fluorine carbon spraying, 91 for electrophoretic painting and 31 for wood treatment lines. Besides these, China also paid attention to the self innovation and its first 7,500 t short-stroke extrusion machine was put into use in 2006. In the same year, China also made its first 1,000 t reverse extrusion machine. Up to the present China owns 20 big extrusion machines of 5,000 to 12,500 t, including those already in use, being installed, or on order. The attractiveness of the Chinese market has also brought numerous suppliers of auxiliary equipment and materials into the country. Especially with more recognition of Chinese aluminium products on the international market and wider applications, most business opportunities for foreign machine manufacturers. According to statistics, so far China has introduced 1,026 extrusion machines from other countries or regions, mainly from Taiwan and Japan since 1980, and this accounts for about 70 percent of the total. Out of this number, 446 machines were for surface treatment, market participants, both at home and abroad, approach China’s market with confidence. Present market situation China’s construction industry has been the driving force of the growing demand for aluminium products. The 75 MARKETS AND TECHNOLOGY main focus is on three aspects: • line-supporting poles and pylons, to reduce total weight • airplane runways, to increase flexibility • satisfying various demands relating to house decoration. China’s apparent consumption of aluminium extrusion products grew by 26.4 percent to 4,080 kt/a in 2006. Among this, aluminium products for building and construction account for almost 70 percent of the total. In 2006 China’s production of automobiles, motorcycles, bicycles, household appliances, microelectronic computers, cell-phones, etc. increased at a headlong pace. Also since 2006, China’s civil aviation project was activated, railway transportation developed at a high rate and highspeed trains entered a new phase. All these sectors provide good market prospects for extruded aluminium products. Yet China’s use of aluminium for building and construction will continue to maintain the leading position, owing to the strong development of China’s construction industry. In 2006 alone, China’s house construction acreage reached 2.1 billion square meters, an increase of 21 percent compared with 2005. Construction acreage is the pioneer index for future aluminium production for building. On average, the house completion acreage has been growing at 4 percent each year from 1995 to 2006. Between 2007 and 2010 China’s real estate investment will grow at an average annual rate of over 15 percent and the house completion acreage will increase by over 10 percent each year. Accordingly, demand for aluminium products by China’s construction industry will increase by a constant 12 percent, corresponding to an additional demand for aluminium of 500 kt/a per year. Statistics show that over 50 percent of China’s new houses are made with aluminium door and window 76 frames. One-third of every 10 million square meters of completed construction acreage each year involves aluminium products and each square meter consumes 15 kg of aluminium. Besides, pipelines, handrails, ladders, decoration parts, etc. also involve large quantities of aluminium products. In the long term, with China’s urbanization and industrialization in the years to come, China’s alumina consumption will continue to increase. It is forecast that aluminium products for building and construction will grow by eight to 15 percent, to 2,430 kt/a, 2,720 kt/a and 2, 940 kt/a in 2005, 2006 and 2007 respectively. Although aluminium extrusion is generally regarded as an energy-intensive industry, the construction acreage increases by two billion square meters each year in China. On the basis that aluminium products for doors, windows and walls account for 30 percent of total construction materials, the prospects for aluminium for construction and building are quite promising in the future, granted the annual increase of about 25 to 30 percent in real estate investment. It is expected that with the coming Beijing Olympic Games in 2008 and the Shanghai World Expo in 2010, China’s demand for aluminium construction products will stay above 3,200 kt/a until 2010. As for China’s demand for aluminium considered sector by sector, the main products are generally aluminium sections, plates and foils, casting, wires, bars and poles. Considering the example year of 2005, China’s total consumption of aluminium products in the construction sector was 2,680 kt, of which 77 percent is for aluminium profiles. Future prospects China, as a large aluminium producer and consumer at present and in the future, has its own undisputed advantages in terms of market consumption and low production cost. Accordingly, some international aluminium companies have already or are planning to set up production bases in China. It is expected that the production capacity and total production of China’s aluminium extruded products will grow by 5.8 percent and 7.5 percent respectively on average from 2007 to 2010, and will reach 6,890 kt/a and 5,520 kt/a by 2010. It is predicted that China’s apparent aluminium consumption for building and construction will reach over 3,000 kt by 2010 and will account for over 60 percent of total aluminium extrusion consumption. This percentage may be a little lower due to rising aluminium consumption for industrial use. Until now, the production and number of companies for aluminium products used in construction still maintains the dominant position in the overall aluminium extrusion industry in China. At present, over 480 enterprises hold formal legal permits to produce aluminium products for building and most of them are privately owned, especially in Guangdong. In the long term aluminium products for construction will still maintain the leading position in the extrusion industry. Author Shi Lili works as a freelance journalist for foreign media and is a consultant for foreign companies interested in Beijing, P.R. of China. Amongst others, she has two years of working experience in the Foreign Affairs Department of China Nonferrous Metals Industry Association (CNIA). ALUMINIUM · 1-2/2008 MARKETS AND TECHNOLOGY Winners of the European Aluminiumin Renovation Award 2007 The European Aluminium in Renovation Award, which ran throughout 2007, involved 15 European countries, a series of national competitions and a European final rewarding the most innovative and sustainable uses of aluminium in building renovation. The winning entries illustrate that whether used to preserve a piece of national heritage or to upgrade the environmental performance of residential or utility buildings, aluminium is the most sustainable solution. The 2007 Renovation Award is an initiative of the ‘Building Group’ of the European Aluminium Association (EAA) and the Aluminium For Future Generations programme in cooperation with national aluminium associations in many European countries. An international jury judged 47 entries nomi- nated by seven national competitions. Five Awards, three Special Prizes, a Jury Prize and one Honourable Mention were given to representatives of the winning projects. Presentation of the awards and other prize winners took place during the Batimat 2007 at the Expo Center Porte de Versailles in Paris. Batimat is Europe’s biggest Expo for Building and Architecture. The concept of aluminium in renovation covered not only renovation, but also restoration and re-construction provided the former structure of the building had been maintained such as changing the function of an existing building, e. g. turning a warehouse into apartments. The following criteria were taken into account when assessing the entries: • Significant use of Aluminium • Contemporary design • Life cycle thinking • Energy efficiency • Socio-economic impact • Added value to the original building In the following a presentation of some of the award-winning projects. Award in the Category Historical Buildings Milan, Italy Aluminium products: Metra Project: The restoration and recovery of the Pirelli building was conducted via a system of interventions which provided the details of the entire operational process in order to verify the formal, performance and technical material qualities, time and costs for execution. Before restoration there was the existing aluminium curtain wall in a stick system with a total surface of approx. 10,800 sqm. The curtain wall is based on a stick system in anodised aluminium in modules 2850 mm in width and 1854 mm in height, completely glazed in opening parts measuring 1900 mm with a chamber and fixed parts measuring 950 mm. In addition, two bands of skylights, above and below, constructed in opaque panels like sandwiches formed with an exterior pane of glass and an internal sheet in galvanised steel, all linked around the perimeter by a rubber gasket and weather strip. Jury judgement: The Pirelli skyscraper is a symbol of modern architecture created by the famous Gio Ponti in the fifties. The building was partly damaged by an aeroplane accident. There has been a special debate in Italy on the methodology for restoration and conservation. The Region of Lombardy decided to proceed using ‘anastylosis’, a reconstruction technique based on careful study and Aluminium Award Private Houses Collective Housing Utility Buildings Public Buildings Historical Buildings Winner Country Maison à Fleury-les-Aubrais France Warehouse Nautilus, Scheveningen Netherlands Café Mayer, Vöcklabruck Austria Rich Mix Bethnall Green, London Pirelli Skyscraper, Milano UK Italy Photos: EAA Pirelli Building Architects: Renato Sarno Group and Corvino+Multari mensuration using original architectural elements where possible. This building is the first example of applying this conservation technique to curtain walling. Furthermore, new performance standards made it necessary to test new possibilities in the use of aluminium. They succeeded in restoring the aluminium where it could be recovered (disassembly, cleaning, re-anodising and re-assembly of the elements). For parts which were destroyed new ones had to be made with the same morphology. This project truly restored as much of the original material as possible as well as meeting the highest of modern building standards. © Special Prize Cladding & Roofing Doors & Windows Curtain Walls Jury Prize Honourable Mention Winner BMW-Hochhaus, München Borgo Wührer Village, Brescia Country Germany Italy Plaza 14 Business Centre, Zaragoza Spain San Ponziano Library, Lucca Casino Kursaal Oostende Italy Belgium The prize winners of the European Aluminium in Renovation Award 2007 ALUMINIUM · 1-2/2008 77 MARKETS AND TECHNOLOGY Award in the Category Public Buildings London, England Aluminium products: Kalzip Rich Mix Bethnall Green Architect: Penoyre & Prasad Project: An East End of London property that has been transformed by the use of external aluminium louvres whilst still maintaining its original facade. Not only has the property been totally transformed but also the internal space has been given a new lease of life by controlling solar gain. Jury judgement: The minimal intervention of the existing building by the use of coloured aluminium louvres has created a completely new and modern view of this complex. It is not only an architectural feature but also a way to control the solar heat. Together with the chosen colours the facade gives a vivid and variable impression. Special Prize for Cladding and Roofing BMW Hochhaus Architect: eS 21 engineering & structure Project: Aluminium cladding of the pre-stressed concrete king pins. One has to be able to open up any such cladding so that the pre-stressed concrete construction can be inspected in future. In addition, because there were only a few points suitable for attaching the large-format cladding components, the components had to have a low structural weight while at the same time the structure had to have a high stiffness. Because of the special geometry, it was necessary to manufacture curved aluminium ribbed shells with a bi-directional curvature. One has to imagine a 3D free-form shape such as in car body manufacturing but significantly larger. Other challenges were the erection at a height of 100 metres under difficult conditions, the high degree of precision and the automation of the manufacturing using welding devices. Munich, Germany Aluminium products: Otto Valenta Jury judgement: This refurbishment shows an innovative way to use aluminium. It is intelligent cladding, completely prefabricated and put into position in short time. Special Prize for Doors & Windows Borgo Wührer Village Architect: Studio Racheli Architetti Project: Recovering the area of the former Whürer factory, even the substitution of the windows required particular attention. The original elements, made of iron and glass, were substituted with a personalised version of an existing aluminium frame system. The use of aluminium gives remarkable advantages in the maintenance, non-deformability as well as in thermal and acoustic insulation. The substitution of the windows improved the thermal and energy-saving performances in the different spaces of the historical factory. On the other hand, it allowed the keeping of the continuity of language present in the images of the industrial complex, which was built in the 1880’s. Jury judgement: The intervention is dedicated to the restoration of an existing industrial complex now converted into mixed commercial use. The design respected the existing arrangement of windows also tackling the new re- 78 Brescia, Italy Aluminium Products: Metra quirements dictated by new energy standards. All of this is done in relation to the significant variety of the existing window frames. This required research of new profiles in respect of the 19th century industrial structures. N ALUMINIUM · 1-2/2008 ENVIRONMENT AND ECOLOGY Friedensnobelpreis für IPCC Ein Quäntchen Ehre auch für Halvor Kvande Halvor Kvande, der im Bereich Primary Production bei Hydro arbeitet, forscht seit vielen Jahren, um das Elektrolyseverfahren für Aluminium zu verbessern. Seine Forschungsarbeiten zielen unter anderem darauf, die Emissionen von CO2 und perfluorierter Kohlenwasserstoffe (PFC) zu reduzieren. Diese Arbeit war Teil eines der letzten Berichte des U. N. Klimapanels IPCC, das zusammen mit dem ehemaligen US-Vizepräsidenten Al Gore den diesjährigen Friedensnobelpreis erhielt. Kvande, der in Oslo arbeitet, ist einer von zahlreichen Forschern aus über 130 Ländern, die ihren Beitrag zu den letzten IPCC-Berichten geleistet haben. Er ist überzeugt, dass dieser Preis das öffentliche Bewusstsein verändern wird, und fügt hinzu: „Er © Nobel Peace Prize for IPCC A small slice of the glory also for Halvor Kvande Halvor Kvande, who works in the Primary Production sector of Hydro, has been working for many years to improve the aluminium electrolysis process. Part of his work includes trying to reduce CO2 and perfluorocarbon (PFC) gas emissions to the atmosphere, and has been included in one of the recent reports from the Intergovernmental Panel on Climate Change (IPCC), which was co-winner of the Nobel Peace Prize for 2007, along with former U. S. Vice President Al Gore. Kvande, who is based in Oslo, is among the many researchers from more than 130 nations who have con- tributed to the writing of these recent IPCC reports. “I strongly believe this prize will make a difference,” he says. “And it can also be seen in light of the ongoing debate and the need for political leadership. Some activists and scientists link next year’s presidential election in the US to the destiny of global environment”. Better control of the production process PFC gases are not made naturally, Kvande points out, and their major source is primary aluminium production. They contribute to global warming, as they prevent the infrared heat loss from the earth passing © www aluminiumePaper.com Please be our guest and discover the benefits of the ALUMINIUM-ePaper yourself in a free three-month trial: • accessible at least a week before the printed edition • available from any location • simple download • keyword researches • linked list of contents • direct contact with advertisers ALUMINIUM · 1-2/2008 79 U M W E LT U N D Ö KO LO G I E Bessere Kontrolle des Produktionsprozesses Perfluorierte Kohlenwasserstoffe entständen nicht natürlich, unterstreicht Kvande, die Hauptquelle für diese Gase sei die Primäraluminiumherstellung. Sie tragen zur globalen Erderwärmung bei, da sie verhindern, dass die Erdwärme in die Atmosphäre abgegeben wird. Die Produktion von einem Kilogramm Aluminium hat gegenwärtig eine Emission von etwa vier Kilogramm CO2 zur Folge. Viele Aluminiumhersteller in der Welt verursachten noch höhere Emissionswerte, sagt Kvande. „Vor 15 bis 20 Jahren war man allgemein der Auffassung, dass die Anodeneffekte in den Elektrolysezellen notwendig waren, damit diese gut funktionierten. Heute wissen wir, dass dies eher ein Zeichen für den schlechten Betrieb der Zellen ist. Die gesamte Branche ist sich darüber im Klaren und Anodeneffekte werden nun als Abweichung betrachtet, die durch präziseres und kontrolliertes Befüllen mit Aluminiumoxid vermieden werden können“, erklärt er. Durch eine bessere Kontrolle des Produktionsprozesses sind diese Emissionen mittlerweile beträchtlich reduziert worden. In Norwegen sei es der Aluminiumindustrie gelungen, den Ausstoß von Treibhausgasen im Zeitraum 1990 bis 2005 um mehr als 55 Prozent zu verringern, so Kvande. Dilemma „Wir müssen uns jedoch das Dilemma eingestehen“, meint er und verweist darauf, dass die steigende Nachfrage nach Aluminium zu noch höheren CO2-Emissionen führen kann, auch wenn diese pro produzierter Einheit zurückgehen. In den vergangenen Jahren hat die weltweite Aluminiumindustrie ihre Produktionsmenge beträchtlich gesteigert – um ganze 31 Prozent in den Jahren 2000 bis 2005. Die Treibhausemissionen konnten im gleichen Zeitraum um sechs Prozent verringert werden. Darin enthalten Foto: Kåre Foss kann auch im Licht der gegenwärtigen Debatte und des Bedarfs für politische Entscheidungen gesehen werden. Einige Aktivisten und Wissenschaftler verbinden die Präsidentenwahl 2008 in den USA mit der Entwicklung der globalen Umwelt“. Halvor Kvande hat dazu beigetragen, das Elektrolyseverfahren für Aluminium zu verbessern Hydro researcher Halvor Kvande has been working for many years to improve the aluminium electrolysis process sind die Emissionen aus der Bauxitgewinnung, der Herstellung von Tonerde, der Anodenproduktion sowie aus dem Schmelzen und Gießen von Aluminium. Laut dem Londoner International Aluminium Institute (IAI) ist die Reduktion um sechs Prozent die Folge einer 56-prozentigen Reduktion der Emissionen von perfluorierten Kohlenwasserstoffen und einer 12prozentigen Reduktion anderer Emissionen pro Tonne produziertes Primäraluminium. „Für uns heißt die Herausforderung, diesen Trend weiterzuführen“, so Kvande. N through the atmosphere. Production of one kilogram of aluminium now causes about four kilograms of CO2 emissions. Many aluminium producers around the world produce even higher emissions than this, Kvande comments. “About 15 to 20 years ago it was generally believed that the anode effects in the electrolytic cells were necessary for good cell operation. Today we may consider them to be a sign of poorly operated cells. The entire industry is now aware of this, and anode effects are now considered as a deviation, which can be prevented by more precise and controlled feeding of aluminium oxide”, he says. Through better control of the production process, these emissions have actually been considerably reduced. In Norway, the aluminium industry has been able to reduce its specific greenhouse gas emissions by more than 55 percent over the period 1990-2005. Dilemmas “We have to be honest about the dilemmas,” Kvande says, referring to how increasing demand for materials can lead to even higher CO2 emissions, despite lower emissions per produced unit. In recent years, the world’s aluminium industry has increased its total output considerably – as much as 31 percent from 2000 to 2005, while its total greenhouse gas emissions were reduced by six percent over that period. This includes emissions for bauxite mining, alumina refining, anode production, aluminium smelting and casting. According to the International Aluminium Institute (IAI), the six percent reduction is the result of 56 percent reduction in PFC emissions and 12 percent in other direct emissions per tonne of primary aluminium produced. “Our challenge is to continue this trend,” Kvande says. N 60.000 Literaturangaben zum Thema Aluminium Kontakt: [email protected] 80 ALUMINIUM · 1-2/2008 Important information for all exhibitors at ALUMINIUM 2008 in Essen OFFICIAL MEDIA PARTNER Giesel Verlag GmbH • Postfa ch 12 01 58 • + %. . . ' ' )%"&")% $$)% 30907 Isernh agen • Deuts che Post AG • PVST H 41947 .A@ )@A <:8 C:@: >@A : :0? @ @C :AB .A . 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luminium Praxis, has been for many years the official media partner and since 2006 the official Fair Newspaper. p p It will publish again the Fair Newspaper for the German speaking audience in September together with of the forthcomingg ALUMINIUM 2008 in Essen. Due to popular demand, APT Aluminium News together will publish a Fair Newspaper edition for the English speaking participants and visitors from with all over the world for the first time. So every participating exhibitor, will benefit from: • Print run of 20,000 copies – instead of 8,000 – • Direct distribution to all visitors from 2006 • Direct distribution to exhibitors in 2008, ahead of the Fair dates • Distribution to hotels in Essen hosting guests as official Fair residence • Distribution to visitors at the entrance as well as inside the Fair grounds by our designated hostesses • Display on the Technical Press stand • Special reference from the organisers With your client target group under one roof at ALUMINIUM 2008, your advertisement with our Fair Newspapers will be reaching effectively every present and visiting potential customer to your business! As you may appreciate, we are constantly working in improving our services to you while keeping costs steady. Yes, we are interested to participate in your Fair Newspapers. 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Sincerely, Your ALUMINIUM 2008 Fair Newspaper Team Giesel Verlag GmbH Postfach 120158 D-30907 Isernhagen Tel. +49 511 7304-142 Fax +49 511 7304-157 [email protected] www.giesel.de U M W E LT U N D Ö KO LO G I E BDI-Studie zum Klimaschutz CO2-Reduzierungspotenzial in NE-Branche nur zu Lasten der Wettbewerbsfähigkeit möglich Vor dem Hintergrund der Klimapolitik der Bundesregierung hat der Bundesverband der Deutschen Industrie (BDI) e. V. McKinsey & Company beauftragt, Kosten und Potenziale zur Reduzierung von Treibhausgasemissionen zu untersuchen. An der Erarbeitung der gleich lautenden Studie haben mehr als 70 Unternehmen und Verbände in Deutschland mitgewirkt. Die Studie identifiziert technologische Ansätze zur Vermeidung von Treibhausgasen und deren Kosten aus Entscheidersicht in den Sektoren Energie, Industrie, Gebäude, Abfall- sowie Landwirtschaft und Transport. Die WVM Wirtschaftsvereinigung Metalle e. V. hat innerhalb des Sektors Industrie in einer speziellen Arbeitsgruppe „NE-Metalle“ gemeinsam mit Mitgliedsunternehmen und McKinsey Vermeidungshebel und die damit verbundenen Kosten für die gesamte NE-Metallbranche identifiziert und bewertet. Ergebnis der Arbeitsgruppe: Bis 2020 können durch Effizienzverbesserung bei der Wärmebehandlung und gradueller Optimierung in der Elektrolyse etwa 1,3 Mio. Tonnen CO2-Äquivalente gegenüber 2004 reduziert werden. Bis zum Jahr 2030 sei sogar eine Reduktion um 1,6 Mio. Tonnen möglich. Davon entfallen rund 1 Mio. Tonnen auf die Wärmebehandlung und 0,5 Mio. Tonnen auf die Elektrolyse. Effizienzverbesserungen durch den Einsatz energiesparender Querschnittstechnologien wie lastgeregelte elektrische Antriebe und Motorsysteme sowie Raumheizung und -beleuchtung spielen nur eine untergeordnete Rolle. Bei steigender Produktion kann durch die Maßnahmen das Emissionsniveau von 15 Mio. Tonnen CO2Äquivalente bis 2030 in etwa konstant gehalten werden. Die Maßnahmen beruhen auf der Abschätzung, welche Durchdringungsrate heute bekannte Energieeffizienztechnik 2020 ALUMINIUM · 1-2/2008 bzw. 2030 haben wird. Bei der Wärmebehandlung ist eine vollständige Durchdringung bei Schmelz- und Homogenisierungsöfen bereits 2020 wahrscheinlich. Insgesamt können damit rund 15 Prozent des für diese Produktionsprozesse heute benötigten Energiebedarfs eingespart werden. In der Elektrolyse ist erst 2030 mit einer vollständigen Umsetzung der Maßnahmen zu rechnen, wodurch etwa fünf Prozent des heutigen Stromverbrauchs eingespart werden können. Allerdings entstehen bis 2020 für Maßnahmen bei der Wärmebehandlung und Elektrolyse Vermeidungskosten von mehr als 20 bzw. 50 Euro je Tonne CO2, so dass die Maßnah- „Bis 2020 können durch Effizienzverbesserung bei der Wärmebehandlung und gradueller Optimierung in der Elektrolyse etwa 1,3 Mio. Tonnen CO2-Äquivalente gegenüber 2004 reduziert werden“ men aus Entscheidersicht unwirtschaftlich sind und die internationale Wettbewerbsfähigkeit beeinträchtigen würden. Auf den längeren Zeitraum bis 2030 berechnet fallen nur die Kosten für Maßnahmen in der Wärmebehandlung auf unter 20 Euro je Tonne CO2. Noch mehr als diese direkten Kosten wird die internationale Wettbewerbsfähigkeit der NE-Metallindustrie durch steigende Strompreise gefährdet. Denn allein solche Maßnahmen in der Energiewirtschaft, die für einen Preis von bis zu 20 Euro je Tonne CO2 verwirklicht werden, erhöhen den Strompreis um Anzeige www.inotherm-gmbh.de weitere acht Euro je Megawattstunde. Die WVM betont daher, dass bei den Maßnahmen besonderes Augenmerk auf die Erhaltung der Wettbewerbsfähigkeit deutscher Unternehmen, vor allem bei energieintensiven Industrien, gelegt werden muss. Die Produktion am Standort Deutschland kann nur gesichert werden, wenn die Kosteneffizienz das entscheidende Kriterium für die Auswahl und den Zuschnitt der Klimaschutzmaßnahmen ist. Hier sind nicht zuletzt sektorübergreifende Rückwirkungen zu beachten, z. B. steigende Strompreise. Die Akzeptanz der Klimaschutzpolitik wird davon abhängen, welche Belastungen der Verbraucher zu tragen hat. Hierzu bietet die BDI-Studie vielfältige Ansatzpunkte. Politisch kommt es bei der Umsetzung der europäischen und deutschen Klimaund Energiebeschlüsse vom Frühjahr bzw. Sommer 2007 darauf an, die Minderungslasten fairer als bisher zu verteilen und am Kriterium der Kosteneffizienz auszurichten. So sollten erneuerbare Energien dort ausgebaut werden, wo die Potenziale noch weitgehend unausgeschöpft sind und der Ausbau mit besonders geringen Kosten verbunden ist. Vor diesem Hintergrund liefert die vorgelegte Studie im Sinne einer „Preisliste“ (Kosten aus Entscheidersicht) hierfür fundierte Orientierungshilfen. WVM-Kontakt: Tel: +49 (0)30 726 207 198 [email protected] 82 CO M PA N Y N E W S W O R L D W I D E Photo: Rio Tinto Alcan Aluminium smelting industry MMC, Chalco and Binladin firm up Saudi smelter plan MMC Corp., Aluminium Corp. of China (Chalco) and Saudi Binladin Group (SBG) have firmed up plans to build a 1m tpy aluminium smelter in Saudi Arabia. The three companies signed an agreement to build the US$3bn smelter in Jazan Economic City (JEC). The companies will form joint venture company Sino-Saudi Jazan Alu- UC Rusal completes five-year casthouse revamp In November UC Rusal completed its casthouse modernisation programme at four smelters, increasing the share of value-added products to 50% of total production volume. The projects began in 2002 and cost about US$130m. This was aimed at increasing the diversity of casthouse products, which now include rolling slabs, extrusion billets, silicon alloys for automotive uses, highly pure alloys for the electrical engineering industry and rolled wire. The four smelters involved are: Sayanogorsk, Krasnoyarsk, Bratsk and Novokuznetsk. The modernisation programme enables them to produce more than 250 new alloys, to enter new markets and to significantly increase their customer base. Feasibility study on metals complex in Kyrgyzstan After its failure to accomplish a similar project in neighbouring Tajikistan, UC Rusal has resumed exploring opportunities for building an energy and metals complex in Kyrgyzstan. In Kyrgyzstan, which has vast hydropower potential, Rusal hopes to create an industrial cluster comprising electricity and aluminium production facilities. With a new feasi- ALUMINIUM · 1-2/2008 bility study, Rusal is effectively revisiting a plan dating back to 2004 when the then Kyrgyzstan president gave the green light for the construction of an aluminium smelter and electricity plants. That scheme had envisaged building two hydroelectric power stations (Kambarata 1 and 2) on the Naryn river and using locally available nepheline instead of bauxite ore as raw material for aluminium production. Project costs were roughly estimated at US$2bn. Point feeder installation at KrAZ completed In November, UC Rusal’s Krasnoyarsk Aluminium Smelter completed the installation of automatic alumina pointfeeders. KrAZ is the first aluminium smelter in Russia based on slotted anode technology equipped with automatic point feeders. The project started in 2004 and cost over US$38m as part of the strategic programme of ecological modernization of KrAZ. Today, all its 1954 electrolytic cells based on Soderberg technology are equipped with automatic alumina point feeders which has reduced fluoride emissions by 10%, tarry substances by 3% and dust by 30%. minium Ltd to undertake the project, with Chalco and a Saudi consortium, including SBG, each taking a 40% stake in the new company. MMC will hold the remaining 20%. The group also intends to build a 1,860 MW power plant at US$2bn to power the smelter. The shares held by MMC, by the Saudi consortium including SBG and by Chalco will be in proportions of 50:30:20 percent. Construction of the smelter and power plant is scheduled to begin during the second half of 2008 and be completed in 2012. Chalco and its affiliate China Aluminium International Engineering Co. will provide alumina technology for the smelter. Indian aluminium industry to receive huge investment by 2012 In November Indian aluminium industry announced it expected to invest Rs1,000bn (US$25bn) over the next five years. Installed capacity will go up from the existing 1.1m tpy to 4m tpy. Consumption of aluminium in India is growing at 18% per year compared with the global 4.4%. By 2015, Indian aluminium use will grow to 2.75m tpy. CVRD gets new name The Brazilian Companhia Vale do Rio Doce (CVRD) has launched a change to its short name. Previously known by its initials, CVRD, the miner will now go by Vale. New Indian smelter expected online by end of March Vedanta’s new 500,000 tpy smelter in the eastern Indian state of Orissa is expected to produce its first aluminium by the end of March 2008. The first 250,000 tpy stage of the smelter should be mechanically complete in February, with the first production in the following month. The smelter will be fed with alumina from a new 1.4m tpy refinery, also in Orissa. The alumina refinery has started production, although Vedanta has encoun- © 83 CO M PA N Y N E W S W O R L D W I D E tered problems getting government approval for mining bauxite in the Niyamgiri hills. Dubal-Mubadala joint venture to build smelter in Algeria A pre-feasibility study on a major aluminium smelter in Algeria initiated by Emirates Aluminium is progressing well, as the company has showcased the proposed model of the project. The smelter will be built in partnership with Algerian state-owned oil and gas company Sonatrach in the new industrial and port zone of BéniSaf in north-western Algeria. The proposed smelter will have an initial capacity of 700,000 tpy with the option of doubling to 1.4m tpy in time. The smelter comprises two potlines, an anode carbon plant, a casthouse, a sea port for major raw material imports and finished product export, bulk raw material unloading, storage and handling facilities, a storage yard for finished aluminium products, a power plant of 2,000 MW (combined cycle, gas-fired) linked to a water desalination plant and auxiliary infrastructure. The Béni-Saf aluminium smelter will be built using highly-efficient, environment-friendly technologies, and the smelter will use Dubal’s advanced DX reduction cell technology. The production of primary aluminum has the potential to initiate a downstream transformation industry with the capacity for many small- and medium sized businesses in Algeria to evolve into sustainable operations. Gulf investment company eyes greenfield project in India Ras-Al-Khaima Investment Authority (Rakia), a provincial investment company of the United Arab Emirates, is planning to invest US$2bn in a Greenfield integrated aluminium complex in the India state of Andhra Pradesh. Rakia has signed an agreement with the Andhra Pradesh Mineral Development Authority for bauxite reserves to feed a planned facility in Visakhapatnam. Rakia is considering a 1.5m tpy alumina refinery and a 350,000 tpy smelter. 84 ENRC opens Kazakh smelter Eurasian Natural Resources Corp. (ENRC) has inaugurated its aluminium smelter in Pavlodar, Kazakhstan, with initial capacity of 62,500 tpy, planned to increase to 125,000 tpy in 2008 and 250,000 tpy by 2011. The project was completed ahead of schedule. The smelter comprises two potlines, a casthouse and anode production. Power is supplied through a sub-division of ENRC’s energy division. Nalco moves ahead with big Indonesian smelter project India’s state-owned National Aluminium Corporation (Nalco) agreed to invest US$3bn in a 500,000 tpy aluminium smelter in the Indonesian province of Sumatra. After signing an MoU due in January, Nalco will conduct a feasibility study on the project. Nalco will build a 250,000 tpy smelter in the initial phase and ramp up to the full 500,000 tpy later. The exact timeline for the plant has not been released. Alumina and other raw materials needed for the smelter will be shipped from India. The project includes the construction of a coal-fired power plant, to produce 3,250 MW of electricity in the first phase, increasing to 5,250 MW eventually. The power plant will need 4.5m tpy of coal. Alcoa and Yangquan Coal team up for aluminium and electricity project Alcoa has entered into a strategic partnership agreement with Shanxi-based Yangquan Coal Industry (Group) Co. to develop an aluminium and electricity project in Shanxi Province. The partnership was inked in Taiyuan City in November, and the two companies discussed financing, management and both upstream and downstream development for a future project. Yangquan Coal is a key coal producer in Shanxi Province that has long adopted meas- Rio looking at Emirates smelter with Adbic Rio Tinto Aluminium has formed an alliance with Abu Dhabi Basic Industries Group (Adbic) to develop a world-class aluminium smelter project in Ruwais, Abu Dhabi. The project has no cost or timetable yet and remains in the planning phase, with only pre-feasibility studies by Bechtel Corp. completed to date. Local reports suggest a 550,000 tpy smelter at an initial cost of about US$5bn. Construction could start in 2008, with production in 2011. The smelter is the second planned for the largest of the United Arab Emirates. Rio eyes greenfield smelter in Cameroon Besides, Rio Tinto Alcan has signed an amended agreement with the government of Cameroon on water resources for a new 1,000 MW hydro power system in the West African country. This paves the way for studies on a potential 400,000 tpy greenfield smelter. Technical studies are complete and an energy contract is at the negotiation stage. A go-ahead decision on the smelter project is expected by the end of 2009. The greenfield project is separate from a previously-agreed brownfield expansion of the existing Edea smelter, a joint venture between the government and Rio. The Edea brownfield project, lifting capacity from 90,000 tpy to 300,000 tpy, continues to make progress. US$8m AP50 fund launched Rio Tinto Alcan has launched an US$8m fund in a move to promote competitiveness among suppliers and contractors developing of its AP50 smelting technology in Quebec’s Saguenay-Lac-Saint-Jean region. The fund, to be managed by the Fonds de Solidarité des Travailleurs du Quebec (FSTQ), meets one of Alcan’s commitments to the government of Quebec in December 2006 to invest US$2.1bn in the Saguenay-Lac-Saint-Jean region over ten years. Rio is proceeding with the construction of a 60,000 tpy US$550m pilot plant known as Complexe Jonquière to develop new smelting technology. ALUMINIUM · 1-2/2008 CO M PA N Y N E W S W O R L D W I D E ures to promote its non-coal operations, and is also backed by abundant bauxite and energy resources in the province. Alcoa has also expressed its confidence that the Alcoa-Yangquan Coal tie represents a win-win situation for both companies, with Alcoa’s advanced technology and management expertise complementing its partner’s abundant resource reserves. Shanxi Province contains approximately 42.11% of China’s total bauxite reserves, much of which is due to be prospected and developed in the near future. N Bauxite and alumina activities MRL will purchase the 33% stake China Minmetals has in Guangxi Huayin at 855m yuan (US$115m) from parent company China Minmetals. Minmetals and Chalco each have a 33% stake in the project, and Guangxi Investment Group Corp. owns the remaining 34%. The stake purchase forms part of Minmetal’s plan to transfer its alumina and aluminium assets to subsidiary MRL. Construction of Guangxi Huayin started in 2005. Photo: AOS Australian bauxite exploration agreement signed Dubai investment group buys German speciality alumina producer Dubai International Capital (DIC), which is the private equity arm of Dubai Holding, acquired the German speciality alumina producer Almatis. The company is headquartered in Frankfurt and has eight manufacturing sites in Germany, the Netherlands, the USA, Japan, China and India. DIC paid more than US$1bn for this deal. It has plans to increase capacity by 20% to around 750,000 tpy by 2010 and is targeting an aggressive expansion into developing markets such as the Gulf region, India and Brazil. The company’s growth prospects are robust, as the majority of future growth in the alumina refractory market is driven by global steel volumes produced. DIC is acquiring Almatis from funds controlled by Rhone Capital and Teachers’ Private Capital, the investment arm of the Ontario Teachers’ Pension Plan. a total capacity of 8.4m tpy of alumina and 0.65m tpy of aluminium hydroxide, by 2015. The decision to build these plants follows a government plan to exploit and process bauxite in the Central Highlands through 2025. The plants will cost US$11.8bn15.6bn. At least US$47.5m would be spent on completing the geological survey, US$9.9-13.7bn for building, exploiting and processing plants and US$1.9bn for building infrastructure. The company developing the project will be equitised, with the Vietnamese government responsible for management. A dedicated port that can load vessels with 50,000 tonnes of product will be built in central Binh Thuan Province to develop the industry in the Central Highlands and Southern Central regions. Environmentally friendly technology will be used to exploit 5.5bn tonnes of bauxite in the Central Highlands provinces. Guangxi Huayin to start trial production Vietnam to build seven alumina processing plants by 2015 Vietnam will build seven alumina refineries and a bauxite-aluminium processing complex, which will have ALUMINIUM · 1-2/2008 Guangxi Huayin Aluminium Co, whose backers of the 1.6m tpy alumina refinery include Chalco and China Minmetals Corp., announced trial production to start in December 2007. Hydro is entering into a joint venture with the Australian mining company United Minerals Corporation (UMC) with the intention of recovering bauxite and producing alumina in Kimberley, Western Australia. The agreement gives Hydro a 75% share in the partnership, which must first finish the ongoing investigations by the end of 2009 within a total cost framework of NOK40m (US$7.4m). If the investigation confirms commercially recoverable deposits the partners will consider setting up a mining company and an alumina company, which may then result in an investment decision. A possible bauxite and alumina project in Australia is in line with Hydro’s strategy to increase the company’s primary aluminium production and step up its production of alumina. MRN reaches full bauxite mining capacity Brazilian bauxite miner Mineração Rio do Norte (MRN) has reached its full capacity production of 17.8m tpy. MRN now expects to stay at this level for the next 30 to 40 years. The company in Para state, north Brazil, has gradually increased its capacity from 16.3m tpy three years ago due to process improvements. MRN is majorityowned by CVRD, followed by Alcan, Alcoa, Norsk Hydro, CBA and BHP Billiton. MRN may start mining at a new mine site in order to ensure continuity of its current production levels. The new mine site could involve a US$100m investment. © 85 CO M PA N Y N E W S W O R L D W I D E Glencore may supply Century with 2.3m tonnes of alumina Vietnam licences US$490m bauxite project Century Aluminum Co., Monterrey, California, and Glencore International AG, Zug, Switzerland, have tentatively agreed on a five-year deal for the supply of 2.3m tonnes of alumina for Century’s smelters. A final purchase agreement is pending, according to a filing made by Century with the U.S. Securities and Exchange Commission. Under the proposed deal, Glencore would supply Century with 290,000 tonnes of alumina in 2010, 365,000 tonnes in 2011, 450,000 tonnes in 2012 and 2013 and 730,000 tonnes in 2014. The price of the alumina will be indexed to the price of aluminium as quoted on the LME. Glencore is Century’s largest shareholder, owning approx. 28.6% of the company’s outstanding shares. In addition to being a supplier, the big Swiss trader is also a Century customer and a counterpart to its hedges. The Vietnam National Coal and Mineral Industries Group has been awarded a government licence to develop a US$490m bauxite mining project in Lam Dong province in the country’s central highlands region. The company is aiming to produce about 600,000 tpy of bauxite with a start-up date in 2010. The Tan Rai bauxite mine in Bao Lam district is estimated to have a reserve of over 176m tonnes. Chinese alumina refineries will pay more for bauxite from Bintan, Indonesia, in 2008, but the increase will pale in comparison to the rise of freight costs. Chandong Chiping Xinfa Huayu Alumina Co. will face an increase of around US$5-6 per tonne for its 2008 contracts with Bintan miners, This will take prices next year to around US$20 per tonne fob Bintan for Chiping. Bauxite prices for Shandong Weigiao Aluminium Co. will not change much at US$18-22 per tonne fob Bintan next year. Refineries in China’s eastern Shandong province are highly dependent on imported bauxites, particularly those from Indonesia. Production cost increases for refineries are mostly due to surging freight costs. Freight costs have risen US$1015 per tonne from around mid-year. Indian bauxite annual contracts are offered at US$70-90 per tonne cif Shandong, compared to US$40-50 per tonne cif Shandong in 2006. Bauxite buyers and sellers typically settle calendar-year contracts near the end of the year. 86 In December JSW Aluminium was close to receiving environmental approval for its 1.6m tpy alumina refinery at Visakhapatnamin in the southern Indian state of Andhra Pradesh. JSW will use Alcan technology at the Rs40bn (US$1bn) project. It plans to set up a refinery in the first phase along with a 90 MW power plant. The company will set up a 250,000 tpy aluminium smelter in the second Investors plan US$750m in African alumina refinery Investors are in talks with unidentified aluminium producers to develop a US$750m alumina refinery in Sierra Leone. The plant may be fed with material from Port Loko, the country’s largest bauxite deposit co-owned by Boulle and Toronto-based Moydow Mines International Inc. and Titanium Resources Ltd.’s nearby Mokanji deposit. The refinery would be built near the deposits northwest of Freetown, and may yield as much as 1.5m tpy. A feasibility study could take as much as 18 months. The Port Loko deposit contains about 100m tonnes of bauxite. N Recycling and secondary smelting Photo: Hydro Chinese refineries to pay more for Bintan bauxite JSW near to winning approval for alumina refinery phase at a cost of Rs60bn (US$1.5bn). The bauxite mining project that will feed the alumina refinery is also believed to have received approval from the Forest Advisory Committee. JSW expected to complete a detailed engineering study for the refinery project by mid-January and physical work to start by March or April 2008. Alcoa sells autocastings unit to private equity fund Alcoa Inc. has sold its automotive castings business to Compass Automotive Group LLC, a company owned by private equity fund Monomoy Capital Partners LP, New York. Financial terms were not disclosed. The business employs about 530 people and has two main operating locations: the Michigan Casting Centre in Fruitport, Michigan, and the Scandinavian Casting Centre in Farsund, Norway. Cohen Alloys faces closure Glasgow-based secondary aluminium ingot producer Cohen Alloys will close unless management can raise enough money to buy the company. The plant ALUMINIUM · 1-2/2008 CO M PA N Y N E W S W O R L D W I D E is located on the Craigton industrial estate in Glasgow, and the owner of the estate is believed to be selling the land. The plant, which is owned by MacGregor & Moir, produces around 140 tpw of ingot: mainly LM 6 and LM 25. This closure would reduce the amount of ingot produced in the UK by around 5,000 to 6,000 tpy. Cohen Alloys has assured customers that it is in business as usual, amid speculation over the company’s future. Rio sells Slovenian castings businesses In November 2007 Rio Tinto Alcan sold two automotive casting businesses in Slovenia to Hidria Rotomatika d.o.o. Terms of the sale were not disclosed. The company’s casting operations in Slovenia employ some 170 people and had 2006 revenue of US$20m. The two units sold were Alcan Koper d.o.o., a wholly owned subsidiary that distributes aluminium die castings to European automakers, and Alcan Tomos d.o.o., in which Rio Tinto Alcan held a 67% stake and which produces aluminium die castings distributed through Alcan Koper. The businesses were no longer a strategic fit with Rio Tinto Alcan’s Engineered Products unit. Hidria, based in Spodnja Idrija in western Slovenia, is using the acquisition to expand its reach in the European automotive sector. Befasa buys Alcasa to form Europe’s third largest secondary aluminium producer Befasa is to buy Aluminio Catalan (Alcasa) to form Europe’s third largest aluminium waste recycling operation with capacity to produce 150,000 tpy of secondary aluminium. The combined company estimates annual sales at €350m (US$512m) based on 2006 figures. The company will be 60% owned by Befasa and 37% by Qualitas Equity Partners, which recently bought Alcasa, with the remaining 3% being held by the senior management. Befasa’s aluminium division booked sale of €228.4m in 2006 and has 95,000 tpy of aluminium ALUMINIUM · 1-2/2008 alloy production capacity with sites in Valladolid and Biscay in Spain, as well as two salt slag recycling operations in Spain and the UK with overall treatment of 20,000 tpy. Alcasa has 55,000 tpy of capacity with sales of €117m in 2006, with an alloy treatment plant in Barcelona, and also owns Trinacria, which has a plant in Krakow, Poland, and is expected to achieve 20,000 tpy treatment capacity by 2008. Chalco expanding secondary aluminium capacity In November Aluminium Corp. of China (Chalco) is increasing its secondary aluminium alloy capacity as it gets ready to commission and then expand its Qingdao plant and then to build another plant in Guangdong province. Chalco will commission its 100,000 tpy plant in Qingdao in eastern China’s Shandong province by the end of 2007. It expects to commission a second phase of 200,000 tpy – which will take the capacity of the Qingdao plant to 300,000 tpy – by 2009. Chalco is also building another secondary aluminium alloy plant in Foshan in southern China’s Guangdong province. The first phase of 110,000 tpy is slated for commissioning by the end of 2008. Capacity of the Foshan project will ultimately be 300,000 tpy, but its schedule will depend on the progress of the first phase. UK products site to close Another UK aluminium manufactured products site at Dolgarrog in Wales looks set to close after the Welsh regional government declined to support a management rescue plan. Dolgarrog Aluminium, which is 100 years old in 2007, is being wound down by administrators, although a search for a potential acquirer continues. The plant, an integrated casting and rolling mill, was originally part of Alcoa but was bought out by its management around five years ago. Management wanted to take full control of the plant but needed financial assistance from the regional government, which declined. Anglo Blackwells to close Anglo Blackwells is to close its Widnes UK facility, after the master alloys producer filed for administration in October 2007. The move is part of a restructuring programme implemented by its US parent company KB Alloys. Anglo Blackwells, which was established as Blackwells Metallurgical in 1869, was acquired by KB Alloys in 1995. In 2005, the company moved most of its business to China, leaving only a handful of staff at the Widnes plant in Cheshire. New Canadian secondary aluminium plant nears completion Molten Aluminium Producer Canada (MAPCAN) is nearing completion of its new secondary aluminium plant in Allison, Ontario. Mapcan is a joint venture between Honda Trading Group and Asahi Seiren Co, and will supply molten metal to the adjacent automotive engine plant. Construction of the new facility was expected to be mechanically complete by the end of last year with full production seen early spring 2008. Alcoa expands recycling capacity Alcoa has broken ground on a new US$22m project at its Can Reclamation facility at its Tennessee operations. Improvements include a new crusher, new delaquering furnace, with supporting building enclosures, utilities and environmental systems. Implementation of this project will increase UBC (used beverage can) molten output capacity by nearly 50%. Alcoa projects it will recycle nearly 14bn aluminium cans in 2007. The Can Reclamation project is expected to be completed over the next 12 to 18 months. Rio opens new can recycling plant in France Rio Tinto Alcan has inaugurated its US$7m remelting furnace for recycling used beverage cans (UBC) © 87 CO M PA N Y N E W S W O R L D W I D E and a new US$15m trimming and slitting machine for beverage can body stock at its Neuf-Brisach site in France. Alcan Speciality Sheet operations include rolling and recycling operations in Neuf-Brisach and Singen in Germany as well as research and development facilities in Voreppe, France, and Neuhausen, Switzerland. The new strategy will include the divesture of six other business units as well. The company expects the sale of the aluminium business to decrease revenue by approx. US$900m, the largest chunk of the overall US$1.2bn Leggett plans to prune overall. Leggett describes itself as the leading inde- pendent producer of non-automotive die castings in North America. Its aluminium group has 20 facilities in the United States and Mexico, including 14 die casting plants, four tool-anddie shops and two finishing and painting facilities. Most of the sites are in the eastern half of the nation. N Aluminium semis China’s total secondary aluminium production is to reach 2.8m t in 2007, up from 2.4m tonnes in 2006. Of the projected amount, about 1.8m tonnes consist of die casting alloys. In 2008, output is expected to rise further to 2.98m tonnes, based on strong demand and increasing scrap supply. Demand is expected to grow in the coming years, especially in the manufacturing sectors such as the automotive industry. Primary aluminium producers are also looking into secondary production now. By 2010, China’s secondary aluminium output may reach up to 3.6m tonnes. Alexin building aluminium billet plant in Indiana Alexin LLC, a start-up company in Bluffton, Indiana, has broken ground on a US$56m aluminium billet casting facility that is scheduled to be operational by November 2008. The plant is expected to produce more than 95,000 tpy of billet from scrap. Alexin will offer billet up to 406 mm in diameter with length up to 7360 mm. Construction has already begun in Bluffton, and all equipment has been ordered and will arrive in July 2008. Alexin will supply billet to soft alloy extruders. Leggett & Platt to sell aluminium business Leggett & Platt Inc., Carthage, Missouri, plans to divest its aluminum business as part of a broader strategy to re-focus the company’s operations. 88 Photo: Hydro China’s output to reach 2.8m tonnes of secondary aluminium in 2007 North America Sapa Industrial Extrusions completes press upgrade Sapa Industrial Extrusions has completed a US$7m rebuilding and upgrade of press number nine at its Cressona, Pennsylvania plant. The project took almost a year to complete and included complete disassembly of the entire press and replacement of all wearable components. The equipment employs indirect extrusion technology with a 5,500 tonne capacity and 406 mm cylinder size. The press and its peripheral systems are now rated to be in ‘as new’ condition. To improve reliability and control of temperature and operating speed, upgrades included significant investment in a new furnace, press control valves and programmable logic controls. Sapa also installed new equipment for consistent stretch control and improved handling systems to protect product finish. Alcoa Defense awarded contract for Naval Design Services Alcoa has been awarded a contract from the Naval Surface Warfare Center’s Carderock Division for design and engineering services. These services will assist in the development of selected assemblies and components of the Littoral Combat Ship (LCS) and other naval vessels, particularly high-speed craft that navigate shallow waters. The U.S. Congress funded the contract in recognition of the design and engineering services that Alcoa Defense has already provided to the Army and the Air Force under the Army Lightweight Structures Initiative and the Advance Aluminum Aerostructures Initiative. Novelis to supply sheet for GM and Chrysler vehicles Novelis Inc., Atlanta, will supply aluminium sheet to General Motors for the hoods and liftgates on the automaker’s Chevrolet Tahoe Hybrid and GMC Yukon hybrid sport utility vehicles. These two models are the world’s only full-sized hybrid SUVs. They weigh about 180 kg less than traditional models, in part because aluminium helps to reduce their weight. Aluminium is also used in the vehicles’ hybrid gasoline-electric drive, ALUMINIUM · 1-2/2008 CO M PA N Y N E W S W O R L D W I D E battery back and related equipment. The company will also supply aluminium sheet blanks for the hoods of Chrysler LLC’s 2008 Chrysler Town & Country and Dodge Caravan minivans. The contract represents the first use of aluminium for Chrysler minivan hoods. The sheet will come from Novelis’ Oswego/New York and Kingston/Ontario plants. Alcoa dedicates new production facility at the plant, an additional US$47m to the local tax base, and a diversification of products creating a bright future for the facility. Installation of the litho line started early in 2007. The line is designed specifically to clean, level, and trim lithographic sheet that is used in the high end printing market for products including magazines, periodicals, brochures, and newspaper inserts. Rio Tinto Alcan sells majority of its European Service Centres Alcoa Warrick operations dedicated a new lithographic cleaning line, celebrating the creation of 50 new jobs Rio Tinto Alcan had received an irrevocable offer for a substantial ma- jority of its European Service Centres distribution business from Amari Metals. Amari Metals is a private US-based company with a significant metal distribution business. Rio Tinto Alcan’s aerospace distribution business I is not included in the transaction. An operation in Spain is also excluded. Rio Tinto Alcan Engineered Products is concentrating its resources on businesses with good potential for growth where it can assume leadership positions through a differentiated product offering. Service Centres business no longer fits in this strategy. The transaction, which is subject to competitive review, is anticipated to close by the end of the first quarter of 2008. Excluding © Stellenanzeige / Job advertisment We are one of the world's leading companies in the field of high-temperature technologies and applications. With a comprehensive portfolio and innovative solutions we take an active part in our customers' future through a worldwide sales network and service presence in Europe, North America and Asia. We are looking for internationally experienced candidates (female/male) for the following two functions High Level Sales Manager Technical Service Manager • Responsible for sales of lining products for the aluminium industry to a defined region and selected multi-national key accounts • Provide worldwide technical customer support and technical sales consulting for selected key accounts • Negotiate long term supply contracts • Determine customer specific technical specifications • Network with liaison offices and agents • Organize customers’ audits • Collaborate with Order Management, Supply Chain Management, and Technical Service functions • Manage contracts with engineering companies for green field and brown field aluminium smelting projects • Advise, train and support the customers in product use • Solve application problems and manage technical claims • Collect and benchmark data on product performance • Initiate ideas for product innovation • International sales experience with the aluminum industry • Support sales in assessing the future demand • Preferably knowledge about use of cathode lining products in primary aluminium smelting pots • Technical education, BS or MS in Engineering: Metallurgy, Ceramics, Electrical or Chemical • Knowledge of market specific rules and requirements • Professional experience in the primary aluminium smelting industry or in a related field providing technical support • Financial and legal understanding • High level of negotiation and communication skills • Fluent in English and German • Know-how in smelter designs, technologies and operations TALENT MAKES CAPITAL DANCE www.el-netconsulting.com • Team player with good presentation skills • Used to working in multicultural environments • Fluent in English and willing to travel If you are interested and wish to join a growing global player, please send your complete application, including resume, information about expected income and availability to the recruiting firm EL-Net Consulting AG. EL-Net Consulting AG • Schumannstrasse 2 • D-81679 München • Tel: +49 (0)89 45 55 46-0 • Fax: +49 (0)89 45 55 46-10 • [email protected] ALUMINIUM · 1-2/2008 89 CO M PA N Y N E W S W O R L D W I D E the aerospace distribution business and Spanish operation, Rio’s Service Centres employ approx. 800 people in 32 sites and 10 countries across continental Europe. The business recorded 2006 revenues of €340m. South America Alucasa to boost output in 2008 Venezuelan aluminium company Alucasa aims to reach installed capacity of 2,000 tpm in 2008 thanks to, investments in upgrades it plans to carry out next year. Alucasa currently produces 1,700 to 1,800 tpm of thin rolled aluminium products. To reach the goal, Alucasa anticipates investments of roughly US$1.9 million in technological, environmental and social upgrades. Europe UC Rusal to construct packaging foil plant in the Moscow region UC Rusal will construct a packaging foil plant near the city of Dmitrov in the Moscow region. The investment costs are estimated at US$20m. The plant will have an overall capacity of 20,000 tpy of packaging foil and will increase UC Rusal’s share of the Russian foil packaging market by up to 66%. Construction will begin in 2008 with first production scheduled for the end of 2009. The foil for the plant will be shipped from Armenal, Sayanal, and Ural foil, UC Rusal’s major foil mills. The new plant will be equipped with technologically advance machinery from the world’s leading manufacturers of machines used for cutting, stamping, lamination, and gluing of foil products. Irish building claims two architectural awards The Source Arts Centre and Library in Southern Ireland has captured two major architectural awards. The new building incorporates a complex façade design using Hydro’s Technal- 90 brand curtain walling. The building has won an Architectural Association of Ireland (AAI) Award and the award for Best Public and Cultural Building, presented at the Irish Architecture Awards. Both awards aim to encourage the highest standards of design, while recognizing projects that have made a significant contribution to Irish architecture. The €10m riverside complex, designed by McCullough Mulvin Architects, has provided the local community with a contemporary and multi-functional building. It integrates an exhibition space, a 250-seat auditorium and stage, and a library and media zone. Alcoa receives NADCAP certification Alcoa has received the National Aerospace and Defence Contractors Accreditation Program’s (NADCAP) approval for ultrasonic inspection and heat-treated forged products at its Samara manufacturing facility in Russia. NADCAP is an industry-managed accreditation programme designed to develop a global aerospace industry supplier base with world-class quality control for special processes. The Samara plant became the second Russian production facility to acquire the right to enter the world aerospace market and work with such customers as Airbus and Boeing. Alcoa’s Belaya Kalitva heat-treated sheet and plate received NADCAP approval in summer 2007. Russia’s KUMZ lands Boeing supply agreement In December JSC Kamensk Uralsk Metallurgical Works (KUMZ) of Russia and its U.S. sales agent, A.S. Mill Products Inc. (ASMP) signed a longterm supply agreement with Boeing Commercial Airplanes. KUMZ has invested more than US$100m over the past two years upgrading casting, rolling and heat-treat capabilities at its Chkalovsky plate facility. The new plant offers horizontal continuous heat treatment, electrical conductivity control, heavy gauge stretching, ultra- sonic inspection and other supporting equipment to produce high-quality aerospace plate products. KUMZ is the largest independent producer of semi-finished aluminium products in Russia and has developed special applications involving aluminiumlithium alloys. The plant can produce aluminium sheet up to 2,500 mm wide and 15 m long. Alcoa delivers lightweight truck bodies to Sip-Well A team from Alcoa’s Auto and Truck Structures business in Hungary delivered specially made new lightweight aluminium truck bodies in three months that were designed and built exactly to customer specifications. These new truck bodies made from aluminium extrusions, castings and plate from Alcoa Köfem, will save weight while increasing payload for Sip-Well of Belgium, a water cooler company which delivers water coolers and water to the home and office market segment. Asia China Zhongfu mulls US$740m aluminium plate plant China’s Zhongfu Industrial Co is considering spending about 5.5bn yuan (US$740m) to expand and upgrade an aluminium plate and strip plant in China’s central province of Henan. The mid-sized aluminium smelter controlled by Dutch-based Vimetco expects to complete the project in three years. The plant would have a capacity to produce 220,000 tpy of aluminium alloy sheet and strip as well as 80,000 tpy of aluminium medium-thick plate. This project would replace a 170,000 tpy low-grade aluminium plate and strip plant, which had already been under construction. Timken supplying bearings for Chinalco rolling mill The Timken Co, Canton, Ohio, has been contracted by Siemens VAI ALUMINIUM · 1-2/2008 CO M PA N Y N E W S W O R L D W I D E metals Technologies Ltd. to supply bearings for two aluminium rolling mills under construction in China for Aluminium Corp. of China (Chinalco). The terms of the contracts, which resulted in orders for Timken’s large bore cylindrical roller bearings, were not disclosed. Timken designed bearings for the two Siemens mills, enabling the customer to install a successful recirculation oil system that improved thermal stability for the four-row cylindrical bearings. Sapa seeks to double capacity at Shanghai plant turing plant in India near Aurangabad in the state of Maharashtra. The plant will begin operation by mid 2009 with one manufacturing line able to produce approx. 600m cans per year. The facility will be positioned strategically to supply two-piece beverage cans for the majority of existing and currently planned beverage can filling lines in India. The plant will be managed by the company’s wholly owned subsidiary Ball Packaging Europe. Chinese aluminium foil maker cancels IPO Heat exchanger strip maker Sapa is investing SK430m (US$68m) to double capacity to 80,000 tpy at its heat transfer plant in Shanghai, China. The investment includes both property and machinery. Planning and procurement are taking place at once with consideration for future demands for heat exchanger material. Another goal is to increase efficiency at the heat transfer plant in Shanghai. Xiashun Holdings Ltd, China’s largest maker of aluminium foil used for food and drink packages, cancelled a HK$2.1bn (US$270m) Hong Kong stock sale after the city’s key index had its worst month since March 2004. Xiashun pulled the IPO because of declining market conditions. The Fujian-based company became the first since June 2006 to cancel an IPO in Hong Kong because of declining interest from buyers. Its decision came after the Hang Seng Index dropped Ball to build beverage can plant in India Suppliers Ball Corp., Broomfield, Colorado, plans to build a beverage can manufac- Hycast to supply casthouse equipment for Qatalum 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 aluminum 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 aluminum smelters of the world. They are available as loose-leaf files and/or CD-roms from the Aluminium-Verlag, Marketing & Kommunikation GmbH in Düsseldorf as well as by online ordering via www.aluweb.de (Alu-Bookshop) from Giesel Verlag GmbH. ALUMINIUM · 1-2/2008 Hycast AS of Sunndalsøra has signed a letter of intent worth US$40m with Fata EPC of Italy for the supply of casting equipment for the new aluminium smelter to be built in Qatar. The agreement includes design and supply of equipment for casting extrusion ingots and foundry alloys. Construction of the casthouse is scheduled to begin in April 2008 and equipment of Hycast is to arrive in Qatar in December 2008, and will be installed over a period of one year. ABB delivers gas insulated substation to EMAL Power and automation technology group ABB has been awarded a US$30 million contract from Emal for the supply of a gas insulated substa- 8.6% in November and as shares of six of the nine companies that completed IPOs in November trade below their offer price. Asia Aluminium mulls extrusion facility in Middle East Asia’s largest aluminium extruder Asia Aluminium Holdings (AAH) is mulling building an extrusion facility in the Middle East. Given AAH’s experience in the business, it could take 12 to 15 months to set up a facility once a project is decided. AAH has not settled on the capacity or location of the plant but the construction sector in Dubai is of good size and will continue to grow in the next five years. There is also potential in Abu Dhabi, Kuwait and Qatar. AAH has a total of 300,000 to 350,000 tpy of extruding capacity in China and recently inaugurated its Zhaoqing works where it is building a 400,000 tpy hot and cold rolling mill. The mill is scheduled for full commissioning by July 2008, after which it will further raise rolling capacity to 700,000 tpy by 2010. N tion (GIS) for the aluminium smelter of Emirates Aluminium Co. (Emal) which is a joint venture between Abu Dhabi‘s Mubadala Development Company and Dubai Aluminium Company (Dubal). Emal’s greenfield aluminium smelter project has a total value of US$4.9bn. The smelter is being built at Al Taweelah, a site close to Abu Dhabi. Site works on the first phase of the smelter began early in 2007. In 2010, when the first phase of the smelter will be completed, it will start to be operational with a capacity of approx. 700,000 tonnes per year. ABB’s contract with Emal within the first construction phase spans the supply of a GIS, the delivery of the control and protection system as well as a substation automation system (SAS). This smelter project represents Abu Dhabi‘s entry into the aluminium industry as it joins the ranks of major regional and international producers. N 91 RESEARCH Multi-temperature measurement of thermoelectric power for characterisation of solute levels in multi-component industrial aluminium alloys O. Engler, M. Clark, Bonn; L. Löchte, Velbert; Z. Lok, Neuss Introduction During industrial processing of aluminium alloys the level of solute atoms dissolved in the aluminium matrix is an important parameter. Elements in solid solution can increase the strength of the material, which is widely used e. g. in the non-heat treatable 5xxx series Al-Mg alloys. In deformed materials, solute elements may affect softening processes (recovery and / or recrystallisation). Second-phase particles, which form from solid solution, are also known to exert strong influence on the materials behaviour during deformation and recrystallisation. However, although the solute level is an important microstructure feature by controlling several materials properties, its experimental characterisation is not that simple. The two most widely used techniques include measurements of the electrical resistivity and the thermoelectric power, TEP. However, both techniques only yield an integral value of solutes, but cannot distinguish between the contribu- 92 tions of various solute elements. It was the purpose of the presented study to combine and advance these two methods, measurements of electrical resistivity and TEP measurements at various sub-ambient temperatures, into a state that industrial multi-component alloys can be characterised with regard to the solute level of up to eight elements. The measurement technique The electrical resistivity, ρ, of an alloy generally consists of two contributions, i. e. (i) a temperature-dependent term ρ0 which is independent of the defect density, including solutes, and (ii) the temperature-independent contribution of solute elements ρd. This empirical observation, known as Matthiessen’s rule [1, 2], leads to the following expression of the electrical resistivity, ρ, of a dilute aluminium alloy containing several alloy elements i as a function of temperature, T: ρ (Τ,ciss ) = ρ0 (Τ ) + Σαi ciss + ρother a metal is subjected to a temperature gradient, electrons at the hot end will have a higher energy than those at the cold end and will hence diffuse towards the cold end so as to lower the total energy of the system. This diffusion leads to a drop in electrical voltage, which counteracts the electron migration until finally a dynamic equilibrium is achieved. In case of a simple geometry as sketched in Fig. 1, the electrical voltage ΔV is proportional to the temperature gradient ΔT [8]: ΔV = SΔT (2) Here, S is a constant, which is also known as the Seebeck coefficient. This so-called Seebeck effect is most often used to measure temperatures by means of thermocouples, where the thermo-voltage for a given combination of materials is a measure for the applied temperature difference. For analysis of solute elements in aluminium alloys the inverse effect is utilised: Here, a constant temperature i (1) ρ0 is the resistivity of high-purity aluminium (2.65 μΩ·cm at 20°C [3, 4]); the quantities ciss indicate the concentration of element i in solid solution. The element-specific resistivity coefficients αi can be found in the literature (e. g. [1, 4, 5]). The term ρother summarises all other contributions from lattice defects such as vacancies, dislocations, grain boundaries and second-phase particles. There are various means to take such effects into account (e. g. [4-7]), which, however, will not be discussed in this paper any further. The thermoelectric power, TEP, of a material is a measure of the magnitude of an induced thermoelectric voltage in response to a temperature difference across that material. When Illustrations: Hydro The amount of solute elements in aluminium alloys can be assessed from measurements of the thermoelectric power (TEP). Under the assumption that the specific TEP signals of individual alloy elements in aluminium depend on temperature in different ways, TEP values obtained at various temperatures can provide a number of independent measurements for the analysis of solute levels in multi-component alloys. This paper describes an advanced setup to characterise solute levels in commercial aluminium alloys by combining measurements of the electrical resistivity with TEP measurements at a number of sub-ambient temperatures. Fig. 1: Schematic representation of the experimental set-up for measuring the relative TEP ΔV for an aluminium alloy with respect to high purity aluminium electrodes after applying a temperature gradient ΔT ALUMINIUM · 1-2/2008 RESEARCH gradient of the order of 10 K is applied to the sample of interest. The resulting – rather small – thermo-voltage is a measure for the amount of lattice defects and, most notably, alloy elements in solid solution. However, as known from thermocouple measurements, attaching a voltmeter to the material in order to measure the thermoelectric voltage as sketched in Fig. 1 involves junctions of different types of metal to another, so that the measured voltage is a contribution from the TEP of the material of interest and that of the electrodes. In the present case the goal is to detect the amount of the solute alloying elements in aluminium alloys, so that the reference electrode material was chosen to be high purity aluminium. The measured relative TEP, ΔS, is then given by: ΔValloy ΔVAl ΔVmeasured ΔS = Salloy - SAl = ⎯⎯⎯ - ⎯⎯ = ⎯⎯⎯⎯ ΔΤ ΔΤ ΔΤ (3) Analysis of the TEP signal of a dilute alloy in terms of the solute concentration is commonly achieved by applying the Nordheim-Gorter equation [8]: Σi ΔSi αi ciss + ΔS ΔS = ⎯⎯⎯⎯⎯ other ρ (T, ciss) (4) ρ is the electrical resistivity of the alloy (see Eq. 1); αi and ciss denote the element-specific resistivity coefficients and the solute concentration of alloy element i, respectively. ΔSi are the element-specific TEP coefficients (see below), while ΔSother is a correction term for the influence of other lattice defects, most notably dislocations. It has to be noted that both techniques – measurement of electrical resistivity and TEP – only yield an integral value of solutes, but cannot distinguish between the contributions of various solute elements. Hence, quantitative evaluations can only be made under the assumption that solely one element contributes to the signal (e. g. [9-11]). Combination of the two techniques will then enable analysing the contribution of two independent elements [12, 13]. Similarly, TEP measurements at two different temperatures has been shown to yield two in- ALUMINIUM · 1-2/2008 dependent signals which, in turn, also allows analysis on two different solute elements [13, 14]. In the presented study these ideas were taken further by combining electrical resistivity measurements with measurements of TEP at several sub-ambient temperatures [15] into a state that industrial multi-component alloys can be characterised with regard to their solute level, for up to eight different alloying elements. Installation of a multi-temperature TEP device A literature survey has shown that for Al-Mg-Mn-Fe-Si the individual binary TEP signals vary significantly with both solute content and temperature (Fig. 2). It is important to note that the manner in which the TEP varies with T and ci is different for each alloying element. The mostly non-linear dependence on T is seen to dominate at sub-ambient temperatures and tends to weaken when higher temperatures are reached, where the overall linear T-dependence of the electrical resistivity part starts to prevail. Therefore, TEP values obtained at different subambient temperatures can indeed provide the required number of independent measurements [15]. Based on the above concept, a new device was designed, constructed by Anatech BV, Sittard (the Netherlands) [16] and finally installed at the R&D Center of Hydro Aluminium in Bonn, Germany (Fig. 3). The set-up consists of two main components, (i) a device to establish the temperature and, most notably, the temperature gradient along the test specimen and (ii) a high-precision voltmeter to measure the resulting low voltage TEP signals with a resolution of below 0.5 nV. The Anatech TEP instrument uses two heat cells which can both be heated with an electric furnace and cooled with liquid nitrogen through a heat exchanger within the furnace block. Thus, the device allows measurements in a temperature range of –190°C to +400°C with a temperature stability of better than 0.01 K. The temperature difference between the two cells can be controlled between 0 and 20 K, with a typical value of 10 K. Samples with standard geometry used for resistivity measurements can be used for the TEP measurements as well. The samples are clamped with a small, constant mechanical pressure on the two high-purity (99.9995%) aluminium electrodes which are in intimate contact with the two heat cells (Fig. 4). The TEP signal is then gripped at these aluminium electrodes. During a typical measurement cycle a temperature difference of 10 K is applied to the two ends of the sample, i. e. to the two furnaces with the two electrodes. The cycle starts at low Fig. 2. Relative TEP ΔS for binary Al-Mg [8], Al-Mn, Al-Si and Al-Fe [13] as a function of solute level ciss measured at various sub-ambient temperatures 93 RESEARCH temperatures with the one furnace having a temperature of –175°C and the other –165°C. This configuration is kept for a couple of minutes until the measured TEP signal remains constant. Then the cells are heated up to the next measuring temperature, and this procedure is repeated for seven temperature combinations from the above-mentioned average temperature of –170°C up to room temperature (25°C). Thus, after one cycle seven TEP signals for seven temperatures are acquired. Unfortunately, only a limited number of the temperature-dependent, element-specific TEP coefficients ΔSi(T) are available in the literature. Therefore, in the present study these parameters had to be measured before multi-component alloys could be analysed. For that purpose a set of binary alloys for the most important alloying elements, Si, Fe, Cu, Mn, Mg, Cr, Zn and Ti were produced, solutionised in order to generate a condition with the entire amount of alloying element in solid solution and finally water quenched. Then the TEP signals of the samples were determined at seven temperatures ranging from –170°C up to 25°C, in exactly the same measuring cycle as described above. Finally, for each of these temperatures and each binary alloy with a known concentration of solutes the resulting specific TEP coefficients ΔSi were calculated with the NordheimGorter equation (Eq. (4)). When now an unknown multicomponent aluminium alloy is probed Fig. 3. Photograph of the opened TEP device including the liquid nitrogen tank installed at Hydro’s R & D Center in Bonn, Germany. at seven temperatures Tj, a system of seven independent equations can be constructed: ΔS (Tj ) = ΣΔS iTj (ciss ) t (5) An additional equation is provided by measurement of the electrical resistivity ρ (Eq. (1)). This set of eight equations is then solved with the help of a least-square minimisation algorithm so as to derive the solute levels ciss of up to eight different alloy elements. Application example In what follows the application to multi-component TEP measurements with the described device will be illustrated for the AlFeSi alloy AA 8011, which is a general-purpose alloy for many packaging applications. Alloy AA 8011 can be produced by the classical route of direct chill (DC) casting followed by hot and cold rolling or, alternativeFig. 4. Photograph of the specimen clamped on the high-purity aluminium electrodes and the heating / cooling cells ready for the TEP ly, by twin roll measurement casting (TRC) 94 with subsequent cold rolling. In general, the TRC process is distinguished from conventional DC material by a much higher level of elements in supersaturated solid solution. Within the framework of the present study AA 8011 sheet produced by TRC has been further processed along two routes differentiated by the amount of solute elements retained in solid solution: (i) material processed along route ‘A’ was cold rolled without inter-annealing, such that most alloy elements were retained in solid solution. In contrast, (ii) material of route ‘B’ was subjected to a high-temperature inter-annealing which was accompanied by precipitation of Si and Fe-bearing particles. Samples taken at final gauge (90 μm) were annealed so as to determine the resistance of the two differently processed materials to softening. For that purpose, the samples were slowly heated up to various temperatures ranging from 200 to 450°C, kept at this temperature for 3 hours and finally cooled down slowly so as to mimic industrial coil annealing treatments. Fig. 5 shows the resulting mechanical properties in terms of yield strength, Rp0.2, and elongation at fracture, A100mm, as a function of the peak metal temperature, MT. Obviously the two different processes applied largely influence the response of the material to annealing. Note that for back-annealed states (H2x) a flat softening curve is generally desired for the sake of process stability. ALUMINIUM · 1-2/2008 RESEARCH For evaluation of the metallurgical reactions controlling the slope of the softening curve combined TEP and resistivity measurements were evaluated for the as-rolled (fully work hardened) condition, the results are summarised in Table 1. It is evident that the solute level of the most important alloy elements, Si and Fe, is significantly higher for route ‘A’ than for route ‘B’. Obviously the high-temperature inter-annealing performed in route ‘B’ leads to heavy precipitation of Si and, particularly, Fe-bearing phases, not unlike the processes occurring during homogenisation in conventional DC processing. With regard to the final gauge properties the high level of solute Si and Fe exerts a strong solute drag retarding the softening reactions, recovery and recrystallisation, in the non-inter annealed material of route ‘A’. Accordingly, back-annealing of non-inter annealed TRC sheet at a temperature of about 270°C offers the possibility to attain material with a strength of about 100 MPa combined with elongation values in excess of 20%. Summary and conclusions This paper describes an advanced set-up to characterise solute levels in aluminium alloys through measurements of the thermoelectric power (TEP) at several sub-ambient temperatures. Under the assumption that the specific TEP signals of individual alloy elements in aluminium display element bulk composition solute level, route ‘A’ Si 0.610 0.268 Fe 0.910 0.046 Cu 0.014 0.012 Mn Mg Cr 0.016 0.0013 0.013 0.005 0.0008 0.009 Zn 0.005 0.004 Ti 0.022 0.004 solute level, route ‘B’ 0.025 0.004 0.012 0.002 0.0008 0.002 0.004 0.019 Tab. 1: Elements in solid solution for AA 8011, compared to the bulk chemical composition (in [wt%]) different variation with temperature, TEP values obtained at various temperatures can provide a number of independent measurements for the analysis of solute levels. In the present study this idea was implemented by designing a set-up for automated TEP measurements in a temperature cycle from –170°C up to ambient temperature. In combination with measurements of the electrical resistivity, TEP measurements at seven temperatures allow differentiation of the solute level of up to eight alloying elements in commercial multi-component aluminium alloys. Acknowledgements This work was in part funded by the German Federal Ministry for Education and Research (BMBF). The authors are grateful to W. D. Finkelnburg for helpful discussions. References [1] D. Altenpohl, Aluminium und Aluminiumlegierungen. Berlin: Springer-Verlag, 1965. [2] P. Ólafsson, R. Sandström, Å. Karlsson, Mater. Sci. Forum 217-222 (1996) 981-986. [3] J. R. Cooper, Z. Vucic, E. Babic, J. Phys. F Metal. Phys. 4 (1974) 1489-1499. [4] F. Kutner, G. Lang, Aluminium 52 (1976) 322-326. [5] J. E. Hatch (ed.), Aluminum: Properties and Physical Metallurgy. Metals Park, OH: ASM, 1984. 1988 [6] H.-E. Ekström, Back annealing of laboratory cast AlFeSi and commercial 1200 alloys: I Sample processing, tensile properties and solute content. Finspång, Sweden: Sapa technical report D01/699, 2001. [7] G. Grimvall, Thermophysical Properties of Materials, p.268, North Holland 1986. [8] J. M. Pelletier, R. Borrely, Mater. Sci. Engng. 55 (1982) 191-202. [9] J. Hasenclever, Einfluß der Fertigungsbedingungen dünner Bänder auf Gefüge und mechanische Eigenschaften von AlMn-1%-Legierungen. Düsseldorf, Germany: VDI Verlag, 1990. [10] N. J. Luiggi, Mater. Trans. 28B (1997) 125-133. [11] S. Tangen, K. Sjølstadt, E. Nes, T. Furu, K. Marthinsen, Mater. Sci. Forum 396-402 (2002) 469-474. [12] Z. J. Lok, A. J. E. Flemming, R. G. Hamerton, S. van der Zwaag, Mater. Sci. Forum 396-402 (2002) 457-462. [13] F. R. Boutin, S. Demarkar, B. Meyer, Proc. 7th Int. Light Metals Congress, Leoben/Vienna. Düsseldorf: AluminiumVerlag, 1987, p. 212-213. [14] Oscarsson, W. B. Hutchinson, H.-E. Ekström, D. P. E. Dickson, C. J. Simensen, G. M. Raynaud, Z. Metallkd. 79 (1988) 600-604. [15] Z. J. Lok, Microchemistry in Aluminium Sheet Production. PhD-thesis, Delft University of Technology, Delft, The Netherlands, 2005. [16] http://www.anatech.nl/ Authors Dr. Olaf Engler, senior scientist, and Michael Clark BSc, technician, are employed at the R & D Center Bonn of Hydro Aluminium Deutschland GmbH. Dr. Lothar Löchte, previous programme manager at Hydro RDB, is now with Erbslöh Aluminium GmbH, Velbert. Fig. 5. Softening diagram for AA 8011 at final foil gauge for two different processing routes (see text for details) ALUMINIUM · 1-2/2008 Dr. Zacharias Lok, formerly at TU Delft, now works as a product engineer for can stock materials at Aluminium Norf GmbH, Neuss, Germany. 95 RESEARCH Entstehung von CO2-Emissionen bei der Herstellung von Aluminium-Walzprodukten vor dem Hintergrund des nationalen Emissionshandelssystems J. Neumeister, Neuwied Ein wesentliches Ziel der derzeitigen Klimapolitik ist die Reduzierung entstehender Treibhausgase. Mit ihr gingen in der nahen Vergangenheit unterschiedliche Maßnahmen einher, um die durch das Kyoto-Protokoll gesteckten Ziele bis 2012 erfolgreich einhalten zu können. Das nationale Emissionshandelssystem stellt eine dieser Maßnahmen dar. Hierüber werden verschiedene Tätigkeiten der Energiewirtschaft und der Industrie bereits durch das TreibhausgasEmissionshandelsgesetz erfasst und unter einen gemeinsamen CO2-Cap gestellt. Um weitere Reduzierungspotenziale zu erschließen, beschäftigte sich ein durch die Aleris Aluminium Koblenz GmbH initiiertes Projekt mit einer Tätigkeit, die bisher nicht vom nationalen Emissionshandel erfasst wurde, und zwar der Tätigkeit zur Herstellung von Aluminium-Walzprodukten. Neben einer ausführlichen CO2-Prozessanalyse relevanter Herstellungsverfahren und der integrativen Betrachtung ganzer Prozessketten wurden Emissionswerte für unterschiedliche Produkte entwickelt (vgl. Neumeister 2007). Diese verhalfen dazu, entsprechende CO2-Emissionen, die bei der Erzeugung von AluminiumWalzprodukten anfallen, vor dem Hintergrund des nationalen Emissionshandels zu beurteilen und zu bewerten. Die betrachteten Prozesse bzw. Prozessketten umfassten sämtliche relevanten Vorgänge zur Erzeugung von Bändern/ Blechen und Platten aus Aluminium. Im Wesentlichen waren dies Prozesse innerhalb der Betriebsbereiche Gießerei, Warmwalzwerk, Kaltwalzwerk und Plattenfertigung. Zusätzlich wurden noch die Bereitstellung von Druckluft, Wasser und der energetische Bedarf von Flurför- 96 derzeugen analysiert. Die Grenze der Bilanzierung stellte die Abgrenzung zur Herstellung von Bändern/Blechen und Platten aus Aluminium dar. Diese wurden innerhalb der Fertigungsbereiche so gewählt, dass Fehler durch Vernachlässigungen, Ausgrenzungen und Abschätzungen minimal waren. Die Grafik (Fig. 1) veranschaulicht bilanzierte Stoff- und Energieströme einzelner Prozesse. entstanden unter der besonderen Berücksichtigung eines ausgewählten Produktionsstandortes. Hierzu wurden sowohl historische Daten im Zeitraum zwischen 2000 und 2005 ausgewertet als auch unterschiedliche Messreihen zur Ermittlung energetischer Verbräuche herangezogen. Die hier gezeigten Ergebnisse basieren auf den genannten Datenerhebungen, die rund 117 Anlagen Fig. 1: Darstellung der berücksichtigten Stoff- und Energieströme zur Ableitung der spezifischen Endenergieverbräuche bzw. der entsprechenden spezifischen CO2-Emissionen Die Betrachtung von Energieverbräuchen bezog sich im Rahmen der Untersuchungen ausschließlich auf den Endenergieeinsatz. Der energetische Einfluss folgender Punkte fand indes keine Berücksichtigung: • benötigte Rohstoffe und entstehende Emissionen zur Erzeugung bzw. Bereitstellung von Erdgas, Diesel, Wasser und Strom durch entsprechende Versorgungsunternehmen • benötigte Rohstoffe und entstehende Emissionen zur Erzeugung bzw. Bereitstellung von Primäraluminium und weiterer Legierungselemente bzw. von verwendetem recycelten Aluminium • menschliche Arbeit, z. B. Maschinenbeschickung von Hand • metabolische Arbeit, z.B. Nährwert von Lebensmitteln • Umweltenergie, z. B. natürliche Beleuchtung oder Beheizung durch passive Solarenergienutzung. Die erfassten energetischen Daten umfassten, zzgl. bereits existierender Studien (u.a. der SFB 525). Die Bestimmung der einzelnen CO2-Emissionen betrachteter Herstellungsverfahren erfolgte über die entsprechend ermittelten spezifischen Endenergieeinsätze. Unterteilt wurden die entstehenden CO2-Emissionen in prozessbedingte und energiebedingte Emissionen (vgl. ZUG 2007). Prozessbedingte Emissionen sind laut Definition „[...] alle Freisetzungen von Kohlendioxid in die Atmosphäre, bei denen das Kohlendioxid als Produkt einer chemischen Reaktion entsteht, die keine Verbrennung ist“ (§13 Absatz 2 ZUG 2007). Es konnte gezeigt werden, dass bei den betrachteten Prozessen keinerlei prozessbedingte Emissionen entstehen. Energiebedingte Emissionen hingegen sind verbrennungsbedingte Emissionen. Die Berechnung dieser Emissionen erfolgt über eine Aktivitätsrate und über einen entsprechenden Emissionsfaktor. Erfolgt die Bestimmung der CO2-Emissionen ALUMINIUM · 1-2/2008 RESEARCH über einen entsprechenden Emissionsfaktor, so wird weiterhin der untere Heizwert in Ansatz gebracht. Werden die CO2-Emissionen über den Kohlenstoffgehalt bestimmt, so ist ein Umsetzungsfaktor für CO2/C von 3,664 (EU 2004) anzusetzen. Innerhalb der Kohlenstoffbilanz wird dabei zusätzlich zwischen biogenen und nicht-biogenen Kohlenstoffen unterschieden. Im Rahmen dieser Arbeit wurde der seitens der Dehst empfohlene Faktor für Erdgas L mit 0,0002015 tCO2/kWhth zu Grunde gelegt; für Diesel wurde ein Emissionfaktor von 0,000270 tCO2/kWhth angewandt. Die hierüber ermittelten CO2-Frachten sind nicht biogen. Biogene Kohlendioxid-Emissionen stehen laut Definition für „Emissionen aus der Oxidation von nicht fossilem und biologisch abbaubaren, organischen Kohlenstoff zu Kohlendioxid“ (§2 Absatz 8 ZUV 2007). Mit anderen Worten: Primärenergieträger wie Erdöl, Kohle und Erdgas bestehen aus sogenannten nicht-biogenen Kohlenstoff laut ZUV 2007 und damit nach Ansicht der Deutschen Emissionshandelsstelle. Anhand des jeweiligen Emissionsfaktors erfolgt dann die Berechnung der spezifischen CO2-Emissionen über die Anwendung des unteren Heizwertes und der entsprechenden spezifischen Aktivitätsrate der jeweiligen Anlagen. Als Ergebnis der Prozessanalyse wurden spezifische CO2-Emissionen unterschiedlicher Anlagen dargestellt und in verschiedenen Produktgruppen zusammengefasst. Für den Fertigungsbereich Gießerei wurden die Arbeitsabläufe des Chargierens, Schmelzens, Haltens, Refinings, Gießens, Abschopfens, Fräsens und Plattierens berücksichtigt (Fig. 2). Anhand entsprechender Produktgruppen wurde ersichtlich, dass die entstehenden CO2-Emissionen im Bereich von 0,017 bis 0,488 tCO2/tAl liegen. Für den Bereich des Warmwalzwerkes wurden die Vorgänge des Erwärmens und Warmwalzen betrachtet. Das sich je nach Produktionsstruktur anschließende Kühlen konnte aufgrund unzulänglicher Daten nicht mit berücksichtigt werden. Basierend auf der sich ergebenden Prozesskette zeigten ALUMINIUM · 1-2/2008 sich CO2-Emissionen von 0,023 bis 0,086 tCO2/tAl. Der im anschließenden Schritt betrachtete Fertigungsbereich des Kaltwalzwerkes beinhaltete die Prozesse des Vor-, Zwischen- bzw. Fertigglühens, des Kaltwalzens, des Längs- und Querteilens, des Reckens und schließlich des Verpackens. Die CO2-Emissionen lagen hier im Bereich von 0,002 bis 0,305 tCO2/tAl. Schließlich wurde noch der Bereich der Plattenfertigung bilanziert. Die hierbei untersuchten Prozesse erstrecken sich auf das Glühen, Kaltwalzen, Härten, Sägen, Recken und die Inspektion der Platten. Das sich ergebende Produktspektrum wurde mit Hilfe eines allgemeinen Pro- duktansatzes definiert und zeigte im Gesamten CO2-Emissionen von 0 bis 0,409 tCO2/tAl. Nach Abschluss der Prozessanalyse wurde ein produktspezifischer Emissionswertebereich ermittelt. Dies erfolgte anhand der aufgestellten spezifischen CO2-Emissionen unterschiedlicher Produktgruppen. Die gesamten spezifischen CO2-Emissionen der Endprodukte Aluminiumband/-blech bzw. Aluminiumplatte ergaben sich über die unterschiedlichen Zusammenhänge der einzelnen Produktgruppen. Der Übersicht halber wurden diese in Fig. 3 dargestellt. Hierbei wurden die maximalen Bereiche der CO2-Emissionen be- Fig. 2: Ergebnis der Prozesskettenanalyse im Fertigungsbereich der Gießerei mit Darstellung entstehender CO2-Emissionen resultierend aus dem jeweiligen spezifischen Endenergiebedarf 97 RESEARCH stimmt. Die ermittelten Bereiche an Emissionswerten ewKaltwalzwerk und ewPlattenfertigung können die Endprodukte Aluminiumband/-blech und Aluminiumplatte repräsentieren. Hierzu gilt: t ewAl-Band/Blech = (0,042 ÷ 0,879) CO2⁄t Al t ewAl-Platte = (0,04 ÷ 0,983) CO2⁄t Al mit ewAl-Band/Blech = Produktspezifischer Emissionswert für Aluminiumbänder/-bleche in tCO2/tAl ewAl-Platte = Produktspezifischer Emissionswert für Aluminiumplatten in tCO2/tAl Weiterhin sollen an dieser Stelle Einflussgrößen genannt werden, die mitunter maßgeblich den zu wählenden Emissionsbereich in unterschiedlichen Produktionsstätten beeinflussen. Diese wären im Einzelnen: (1) Technologien der vorhandenen Anlagen. Wesentlich beeinflusst wird der Emissionswert hierbei durch unterschiedliche Schmelzanlagen wie regenerative, rekuperative, KaltluftBrenner und induktive Systeme, aber auch verwendete Brennertypen an den eingesetzten Glühöfen (2) Technischer Zustand der verwendeten Anlagen. Maßgeblich ist hier der Zustand der Wärmedämmung eingesetzter Ofenanlagen, aber auch der Zustand verwendeter Brenner (3) Schmelz- und Glühprogramme nehmen aufgrund unterschiedlicher Temperaturverläufe und festgelegter Zeiten Einfluss. Ausschlaggebend ist an den Schmelzanlagen die vorhandene Fuchstemperatur und die gewählte Überführungstemperatur. Letztere nimmt wiederum Einfluss auf den jeweils nachgeschalteten Halteofen (4) Produktionsspezfische Einflussgrößen wie die Auslastung der un- Fig. 3: Darstellung der Herleitung möglicher Emissionswerte auf Basis der aufgestellten Produktgruppen terschiedlichen Anlagen, vorhandene Wartezeiten voneinander abhängiger Anlagen, unterschiedliche Prozessketten (5) Legierungen nehmen Einfluss durch Vorgabe der zu wählenden Schmelz- und Glühprogramme sowie die Bestimmung der notwendigen Walzparameter. Weiterhin sind in diesem Zusammenhang unterschiedliche physikalische Eigenschaften von Bedeutung (6) Ausgangsmaterial hat Auswir- Min. Max. Min. 2000 1.420.067 59.643 1.248.239 54.146 2.166 53.226 61.809 2001 1.431.031 60.103 1.257.876 54.240 2.170 53.318 62.273 2002 1.544.069 64.851 1.357.237 64.589 2.584 63.491 67.434 2003 1.596.788 67.065 1.403.577 71.350 2.854 70.137 69.919 2004 1.632.388 68.560 1.434.869 77.659 3.106 76.339 71.667 2005 1.693.858 71.142 1.488.901 77.544 3.102 76.226 74.244 Max. 1.301.464 1.311.194 1.420.728 1.473.714 1.511.208 1.565.127 tAl Band/Blech (0,2 – > 6mm) tCO2 Min. Max. tAl Platten (> 6mm) CO2-Emissionen in Summe tCO2 tCO2 kungen aufgrund der unterschiedlichen geometrischen Abmessungen und der hierüber beeinflussten Wärmeübertragungsflächen innerhalb der Öfen, aber auch innerhalb weiterer Prozesse wie der Walzvorgänge, des Sägens etc. Zu beachten ist, dass die hier abgebildeten Emissionswerte den maximal möglichen Bereich innerhalb der Produktion von Aluminium-Walzprodukten angeben. Die oben genannten einschränkenden Kriterien sind folg- Tab. 1: Zusammenstellung der Ergebnisse der Hochrechnung möglicher CO2-Emissionen produzierter Aluminium-Walzprodukte auf Basis der Produktionsdaten von 2000 bis 2005 unter Anwendung der aufgestellten Emissionswerte 98 ALUMINIUM · 1-2/2008 RESEARCH lich bei der Wahl des Wertbereichs heranzuziehen. Zur Abschätzung der Einflussnahme der Erzeugung von Aluminiumbändern/-blechen und -platten auf die nationale Allokation erfolgte eine Hochrechnung in Anlehnung an die laut Gesamtverband der deutschen Aluminiumindustrie (GDA) berichteten Produktionsdaten der Aluminiumhalbzeuge. Die Tab. 1 fasst dies noch einmal zusammen. Analog zu der Produktionsentwicklung erzeugter Bänder/Bleche und Platten verzeichnet sich ein Anstieg der CO2-Emissionen von 2000 mit maximal erwarteten 1.301.464 tCO2 auf 2005 mit maximal 1.565.127 tCO2. Die Ergebnisse machen deutlich, dass es aufgrund des erheblichen Spektrums an möglichen CO2-Emissionen der unterschiedlichen Produkte schwer sein wird, diese mittels eines gemeinsamen Emissionswertes zusammenzufassen. Im Rahmen des nationalen Emissionshandels ist es daher fraglich, ob eine Vereinheitlichung bei einer Verpflichtung der Aluminium verarbeitenden Industrie an den CO2-Zertifikatshandel über einen gemeinsamen Produkt-Emissionswert, sprich BVT-Produktbenchmark, erfassbar sein wird. Größere Abweichungen von einem gemeinsamen Emissionswert würden im Rahmen der Zuteilung zu erheblichen Ungerechtigkeiten für einzelne Betreiber führen und somit zu einem wirtschaftlichen Ungleichgewicht beitragen. Die politische Tendenz allerdings läuft derzeit stark auf die Vereinheitlichung für unterschiedliche Produkte hin. Für den Aluminium verarbeitenden Prozess bleibt anzuraten, entweder auf Basis der hier erzielten Ergebnisse und zukünftiger Analysen einen Benchmarkansatz zu entwickeln, der mittels eines Ausgangswerts ein eingeschränkteres Spektrum als das hier ermittelte für eine Zuteilung von CO2-Zertifikaten vorsieht, oder aber zu versuchen, eine Zuteilung über die Festlegung unterschiedlicher Produktgruppen zu erzielen. Auf Basis der hier ermittelten CO2-Emissionen der deutschen Aluminium-Walzwerke soll nun der Einfluss auf die nationale Allokation kurz diskutiert werden. Die Anlagen ALUMINIUM · 1-2/2008 Tätigkeit CO2- Emissionen [tCO2/a] Feuerungsanlagen Roheisen und Stahl Raffinerien Zementklinker Kalk Papier, Karton, Pappe Glas Keramische Erzeugnisse Aluminium Walzprodukte Zellstoff 380.531.645 32.155.159 23.761.135 20.433.336 9.672.669 4.710.677 3.928.428 1.883.097 1.565.127 305.828 Tab. 2: Gegenüberstellung der maximal erwarteten CO2-Zertifikatsmengen für die Tätigkeit der Erzeugung von Aluminium-Walzprodukten im Jahr 2005 zu den weiteren Tätigkeiten im nationalen Emissionshandel nach TEHG 2004. der Aluminium-Walzwerke wären in diesem Sinne als zusätzliche Neuanlagen anzusehen. Unter der Annahme eines konstanten Mengengerüstes bei vorangegangener Einplanung dieser Anlagen von rund 11 Mio. tCO2 laut NAP II soll diese Menge für die weitere Beurteilung herangezogen werden. Ebenfalls wird bei der Betrachtung sowohl von den maximal als auch minimal möglichen CO2-Emissionen ausgegangen. Bezieht man diese für 2005 ermittelten CO2-Emissionen von 74.244 tCO2 bis 1.565.127 tCO2 auf den laut ZUG 2012 vorgegebenen CAP für zusätzliche Anlagen, so ergibt sich ein Anteil von rund 0,67 bis 14,2%. Dies würde bedeuten, dass bei den jährlichen Zertifikatsmengen der Jahre 2008 bis 2012 für die zusätzlichen Anlagen bis 14,2% der Mengen auf die deutschen Aluminium-Walzwerke entfallen könnten. Legt man an dieser Stelle das ermittelte Maximum der hochgerechneten CO2-Emissionen für eine Zuteilung ohne die Berücksichtigung etwaiger anteiliger Kürzungen zu Grunde und stellt dieses den übrigen Tätigkeiten nach TEHG 2004 für das Jahr 2005 gegenüber (vgl. Tab. 2), so lässt sich erkennen, dass die angefallenen Mengen, zusammen mit den aus den keramischen Erzeugnissen und der Zellstoffproduktion resultierenden Emissionen, im unteren Bereich zu finden sind. Hierbei darf nicht außer Acht gelassen werden, dass Tätigkeiten wie die Erzeugung von Zellstoff mit rund 305.828 tCO2 bereits am Handelssystem teilnehmen und somit aktiv an der Einhaltung der getroffenen Minderungspflichten mitwirken. Kuhn/ Thielen 2003 berufen sich in diesem Zusammenhang auf die Minderung spezifischer CO2-Emissionen und die hierüber eingehaltene Selbstverpflichtung der Aluminiumindustrie am Beispiel der Firma Aluminium Norf GmbH in Neuss. Eine Minderung der CO2-Emissionen bezieht sich im Sinne des nationalen Emissionshandels allerdings nicht auf spezifische CO2-Emissionen, sondern stets auf absolute Mengen. Die Senkung der spezifischen CO2-Emissionen ist somit stets der Entwicklung der Produktionsmengen gegenüberzustellen. Die durchgeführte Bilanzierung am Beispiel des betrachteten Aluminium-Walzwerkes hingegen zeigte eine jährliche Zunahme der gesamten CO2-Emissionen im Mittel der Jahre 2000 bis 2006 von rund 1,4%. Abschließend ist festzuhalten, dass eine mögliche Teilnahme der Tätigkeiten zur Erzeugung von Aluminium-Walzprodukten keine gravierende Auswirkung auf die gesamte nationale Allokation haben wird. So könnte sich diese allerdings in der Anpassung des zugrunde gelegten Erfüllungsfaktors äußern. Die zusätzlichen Mengen wären mitunter auf die bisher teilhabenden Unternehmen umzulegen. Inwiefern dies hin zu einer verstärkten Verkürzung des Marktes führt, bleibt abzuwarten. Vermutlich werden zusätzlich über CDM- und JI-Maßnahmen generierte Zertifikate, die innerhalb der zweiten Handelsperiode von 2008 bis 2012 bis zu einem Anteil von 22% (vgl. ZUG 2012 §18 Satz 1) genutzt werden können um die Abgabepflicht zu erfüllen, diesen Verkürzungseffekt ausgleichen. Eine im Rahmen dieses Projektes 99 NEW BOOKS entstandene Dissertation mit dem Thema „CO2-Prozessanalyse von Aluminium-Walzprodukten und Ansätze für eine CO2-arme Produktion“ (Neumeister 2007) wird Ende des ersten Quartals 2008 veröffentlicht. Diese beschäftigt sich neben der hier erwähnten Ableitung von Emissionswerten für Aluminium-Walzprodukte auch hinsichtlich der Einhaltung des nationalen Klimaschutzziels mit Möglichkeiten der CO2-Minderung innerhalb der Produktionabläufe von Aluminium-Walzwerken und berücksichtigt dabei auch erstmals die Anwendung einer CO2-Abscheidung. Diese Thematik wird in der nächsten Ausgabe dieser Zeitschrift aufgegriffen. Quellen (1) ZUG 2007: „Gesetz über den nationalen Zuteilungsplan für Treibhausgas-Emissionsberechtigungen in der Zuteilungsperiode 2005 bis 2007“, Bundesgesetzblatt, Jg. 2004, Teil I Nr. 45, Bonn 30.08.2004. (2) ZUG 2012: „Gesetz zur Änderung der Rechtsgrundlagen zum Emissionshandel im Hinblick auf die Zuteilungsperiode 2008 bis 2012“, Bundesgesetzblatt, Jg. 2007, Teil I Nr. 38, Bonn 10.08.2007. (3) ZUV 2007: „Verordnung über die Zuteilung von Treibhausgas-Emissionsberechtigungen in der Zuteilungsperiode 2005 bis 2007“, Bundesgesetzblatt, Jg. 2004, Teil I Nr. 46, Bonn 31.08.2004. (4) TEHG 2004: „Gesetz zur Umsetzung der Richtlinie 2003/87/EG über ein System für den Handel mit Treibhausgasemissionszertifikaten in der Gemeinschaft“, Bundesgesetzblatt, Jg. 2004, Teil I Nr. 35, Bonn 14.07.2004. (5) Kuhn; Thielen 2003: „FachberichteEnergieeinsparung und CO2-Minderung in einem integrierten Aluminium-Walzwerk“, P. Kuhn, St. Thielen, in: Gaswärme International, Bd. 52 Nr. 8, Gaswärme Institut, Essen 2003, S.508- 514. (6) EU 2004: „Entscheidung der Komission vom 29/01/2004 zur Festlegung von Leitlinien für Überwachung und Berichterstattung betreffend Treibhausgasemissionen gemäß der Richtlinie 2003/87/EG des Europäischen Parlaments und des Rates“, Komission der Europäischen Union, Brüssel 29.01.2004. (7) Neumeister 2007: „CO2-Prozessanalyse von Aluminium-Walzprodukten und Ansätze für eine CO2-arme Produktion“, J. Neumeister, Eingereichte Dissertation an der Fakultät für Maschinenwesen der Ruhr Universität Bochum, Bochum 2007. (8) Sonderforschungsbereich SFB 525, Ressourcenorientierte Gesamtbetrachtung von Stoffströmen metallischer Rohstoffe, RWTH Aachen, 1997-2002, Aachen. Autor Dipl.-Ing. Jens Neumeister studierte Maschinenbau an der Fachhochschule Koblenz (Vertiefungsrichtung Energie- und Umwelttechnik), mit nachfolgendem Ergänzungsstudium an der Technischen Universität Clausthal. Sein Promotionsverfahren zum Dr.-Ing. wird in Kürze abgeschlossen sein. Seit 2006 betreibt er das Ingenieurbüro Neumeister in Neuwied mit den Schwerpunkten energetische Beratung im industriellen Kraftwerksbereich/Papierindustrie sowie Unternehmensbetreuung im CO2-Zertifikathandel. In der Zeit von 2006 bis zum Jahreswechsel 2008 war Neumeister in der Abteilung „Technische Dienste“ der Aleris Aluminium Koblenz GmbH in Koblenz tätig, in der er das hier vorgestellte Projekt leitete. In dieser Zeit schrieb er seine Dissertation, die vom Lehrstuhl für Energiesysteme und Energiewirtschaft der Ruhr-Universität Bochum betreut wurde. Pre-painted Aluminium in Exterior Architecture This book is meant to be an introduction to a subject, which so far has not been covered in detail in technical or architectural professional literature. The segment of surface-treated, semi-finished aluminium rolled products for high-tech, post-formable architectural applications since more than 40 years has grown into a sizable business and has increased substantially in complexity. Conventional education on the engineering or architectural side can hardly cope with the pace of new ideas and developments constantly coming up in this innovative industry. Therefore, the book is intended to provide a not too scientific, up-to-date and systematic overview (as of 2007) of facts and data compiled from various sources. Also, modern means of information have been integrated for further studies or research of the latest 100 developments by means of electronic means (internet research / email addresses) via respective trade names or relevant industry publications, which usually tend to be close to the latest developments. The book can be used as reference and study guide by a wide range of professionals. The focus is on architects, specifiers, planners, consultants, building owners, metal builders or procurement personnel as well as on apprentices, trainees and newcomers to the subject. A general overview is given about the specific range of prepainted aluminium rolled products for exterior architecture from fabrication of the semi-finished product to installation of the finished products. Readers will become familiar with the comprehensive technical terms used in this market segment, while decision makers will be enabled to differentiate between the options between respective technologies and qualities resulting from that. An insight is being given into the versatility of pre-painted aluminium for roof and wall claddings. The variety of applications is shown to understand the technical aspects, which should lead to economical construc- ALUMINIUM · 1-2/2008 NEUE BÜCHER tions with their specific advantages of pre-painted rolled products versus other options. There are differences in designs, product philosophies and qualities leading to individual solutions and price levels of the end products installed. As pre-painted aluminium sheets are expected to have a larger share in architecture than before this book is intended to illustrate the advantages of pre-painted aluminium rolled products, designed for decorative purposes. Readers will profit from this accumulated know-how and be encouraged to consider pre-painted aluminium sheets to be an interesting and advantageous option in their planning considerations for exterior roof and wall claddings. The author Fred-Roderich Pohl is an acknowledged expert whose busi- ness career has been closely connected with the promotion of pre-painted aluminium for architectural purposes for many decades. F.-R. Pohl, Pre-Painted Aluminium in Exterior Architecture, ISBN 97887017-288-6, 1. edition 2007, 160 p., € 67,- plus shipping costs. This book can also be ordered via Giesel Verlag website: www.aluweb.de (Alu-Bookshop). Handbuch zur Industriellen Bildverarbeitung Die Fraunhofer-Allianz Vision, Erlangen, hat anlässlich ihres 10-jährigen Jubiläums das „Handbuch zur Industriellen Bildverarbeitung – Qualitätssicherung in der Praxis“ herausgegeben. Das Buch gibt einen Überblick über die industrielle Qualitätssicherung mit automatischer Bildverarbeitung und ist sowohl zur Unterstützung von Entscheidungsträgern als auch von Anwendern gedacht. Neben Fachaufsätzen komplettieren eine Anbieterübersicht und ein Referenzteil zu Fachliteratur, Fachzeitschriften, Messen, Veranstaltungen usw. das Handbuch. Die Leitfaden-Reihe zur Bildverarbeitung der Fraunhofer-Allianz Vision hat sich in den letzten Jahren fest etabliert. In der Vergangenheit wurde jährlich ein Leitfaden herausgegeben, der jeweils einen Aspekt neuer Entwicklungen in der industriellen Bildverarbeitung in möglichst verständlicher Form unter Einbindung von Praxisbeispielen beleuchtet hat. Anlässlich des 10-jährigen Jubiläums der Allianz erscheint statt eines Leitfadens dieses komplette Buch, das das aktuelle Wissen der industriellen Bildverarbeitung bündelt. Besondere Beachtung finden auch die zukunftsträchtigen und noch nicht so verbreiteten Techniken zur Inspektion unter der Oberfläche und zur berührungslosen dreidimensionalen Vermessung von Werkstücken bis in den Nanometerbereich der Oberflächenstrukturen. Das Buch bietet eine anwendungsbezogene Mischung aus Theorie und ALUMINIUM · 1-2/2008 Praxis. Die Beiträge stammen von erfahrenen Wissenschaftlern und sind nicht nur für Anwender, sondern auch für Ingenieure und Studierende interessant, bei denen Überlegungen zum praktischen Einsatz der Techniken in der industriellen Umgebung im Vordergrund stehen. Im ersten Teil werden zunächst einige Grundlagen der Bildverarbeitung vorgestellt. Der Bogen spannt sich von technischen Voraussetzungen über Wirtschaftlichkeitsbetrachtungen bis hin zu praktischen Tipps für den Einsatz von Bildverarbeitungssystemen im Betrieb. Es folgen ein Überblick über momentan verfügbare Bild-Sensoren (Zeile, Matrix, CMOS, Röntgen, 3-D, Infrarot usw.) sowie über Optiken und Beleuchtung. Abgeschlossen wird der erste Teil mit Betrachtungen zum Thema Software. Die folgenden Kapitel behandeln anwendungsbezogene Themen. Die Einteilung orientiert sich an der Fragestellung, was bzw. welcher Bereich von Werkstücken geprüft werden soll (also Oberflächen, Abmessungen usw.) und wie (also mit welcher Prüfmethode) die Prüfung stattfinden soll. Zunächst geht es um die äußerliche Prüfung von Werkstücken: Oberflächenprüfung und Charakterisierung von Mikrostrukturen auf Oberflächen. Danach werden Methoden der berührungslosen Messtechnik vorgestellt, mit denen Werkstücke dreidimensional vermessen und auf Maßhaltigkeit geprüft werden können. Anschließend werden dann Methoden beschrieben, mit denen man Bereiche in Werkstücken, die äußerlich nicht sichtbar sind, unter- suchen kann. Zum einen können mit Wärmefluss-Thermographie Fehler unterhalb der Oberfläche detektiert oder auch Schichtdicken vermessen werden. Zum anderen erlaubt die Röntgentechnik die Untersuchung und Vermessung des Inneren von Werkstücken. Schließlich wird noch ein Blick in die Zukunft geworfen: Die Terahertz-Tomographie befindet sich noch im Entwicklungsstadium, verspricht aber für die Zukunft interessante und insbesondere die Röntgentechnik ergänzende Perspektiven, denn THz-Strahlung durchdringt Papier, Keramiken und Kunststoffe und wird von metallischen Leitern und Wasser absorbiert. Vorteilhaft gegenüber Röntgenstrahlung ist, dass diese Strahlung extrem energiearm und somit nichtionisierend ist. Im Anschluss an den Textteil folgt das Kapitel „Anbieter-Porträts“. Maßgebliche Firmen, die Systeme und Lösungen zur Bildverarbeitung und optischen Messtechnik anbieten, werden hier in standardisierter Form porträtiert, so dass der Leser bei Bedarf geeignete Kontaktdaten und Adressen zur Hand hat. Den Abschluss bildet das Kapitel „Referenzen“ mit einer Zusammenstellung wichtiger Quellen zur Bildverarbeitung wie Fachliteratur, Zeitschriften, Messen und Veranstaltungen. Handbuch zur Industriellen Bildverarbeitung – Qualitätssicherung in der Praxis, Fraunhofer IRB Verlag, 513 S., geb., 4-farbig, ISBN: 978-3-81677386-3, Preis € 52,00. Bezug: Büro der Fraunhofer-Allianz Vision (vision@ fraunhofer.de) oder Buchhandel. 101 V E R A N S TA LT U N G E N Review Incal 2007 – 3rd International Conference on Aluminium 21 to 23 November 2007, Hyderabad, India In his keynote address President of Aluminium Association of India, Debu Bhattacharya (also Managing Director of Hindalco Industries Ltd., the aluminium major in India) spoke about India’s role in the aluminium world of tomorrow. He referred to India as a desired destination, the attractiveness of India as a manufacturing centre and the aluminium industry’s role in India. The attractiveness of the aluminium industry in India and its potential set the tone for the other lectures to follow. An exhibition with spread over 2,000 m2 of space and over 50 participating exhibitors and a conference with 12 plenary lectures and 44 presentations in 2 parallel session threads were offered to the more than 700 delegates. The plenary talk of ‘Development of Aluminium in India: Science and Technology Roadmap’ by M. Goel of the governmental Department of Science and Technology gave some vital facts and figures: present annual production exceeds 1.2m tonnes, targeted production is 6m tonnes in the year 2020. The “need for developing an integrated technology roadmap for addressing energy efficiency concerns and promotion of environmentally friendly technologies” was highlighted. An in-depth analysis of demand and supply of various commodities and with particular focus on aluminium was presented by Paul Robinson of CRU UK. The challenges to the downstream industries in aluminium was brought out in detail by Richard Brandtzaeg, Norsk Hydro. Conspicuous in other plenary sessions was the importance given to issues related to energy and environment; especially the carbon credit scheme presented by C. Cornier, a representative from the World Bank, on ‘Carbon finance business-Al sector in India’ attracted a lively discussion. Other plenary talks dealt with the current state of the art and trends in the aluminium industry. The exposition on automotive applications by K. H.von Zengen, EAA, was received with great interest. The papers presented in the parallel regular sessions covered the entire range of topics in the areas of production and recycling of aluminium, extrusion, dies, castings and forging. Over 60 percent of contributions by overseas speakers – notably those from the U. S. and Europe – in the sessions gave the conference a very international character. The organisers made an excellent job of the conference and fair by offering technical sessions and an exhibition of the highest standards and a forum for concerted interaction and personal networking to the participants. An extensive coverage by print and visual media ensured that adequate attention was drawn to the programme not only within the participants, but the outside public in India as well. The forum was extended to the light cultural programmes and banquets. The facilities offered by the Hyderabad International Convention Centre and the adjoining five star hotel made the conference memorable not only in terms of exchange of information and ideas concerning technical and economic issues but also in terms of convenience and comfort. As was mentioned in the closing session, those who missed Incal 2007 will have to wait for the next Incal in 2011. For details of Incal 2007 see http://www.aluminium-india.org/INCAL_07.pdf or contact [email protected] M. Pandit, Kaiserslautern RWTH Update-Seminar Einführung in die Technologie des Aluminiums 11. bis 13. Februar 2008, Aachen Das aec – aluminium engineering center aachen, die RWTH International Academy GmbH und der Gesamtverband der Aluminiumindustrie e. V. (GDA) veranstalten gemeinsam ein weiteres Mal das Fortbildungsseminar „Einführung in die Technologie des Aluminiums“ in verschiedenen Instituten der RWTH. Auch diesmal referieren namhafte Professoren der RWTH Aachen über die Metallurgie, Herstellung, Verar- 102 beitung und Anwendung von Aluminium. Ergänzt werden die Vorträge durch praktische Versuche. Im Laufe der Veranstaltung wird, ausgehend von metallkundlichen Grundlagen, die gesamte Prozesskette durchlaufen, angefangen von der Erzeugung von Primäraluminium über Gießprozesse, der Umformung von Aluminiumbändern bis hin zur Beschichtung und Prüfung fertiger Bauteile. Die Teilnehmer erhalten sowohl auf theoretischer als auch auf praktischer Ebene einen umfassenden Überblick über die einzelnen Glieder in der Prozesskette. Bei erfolgreicher Teilnahme stellen die Veranstalter eine Teilnahmeurkunde aus. Das Seminar richtet sich in erster Linie an Naturwissenschaftler, Ingenieure und Techniker aus der Aluminiumindustrie und der Aluminium verarbeitenden Industrie ohne ausgeprägten werkstoffwissenschaftlichen ALUMINIUM · 1-2/2008 EVENTS Hintergrund, eignet sich aber auch für Kaufleute z. B. aus Vertrieb und Einkauf, die sich einen technischen Überblick über den Werkstoff Aluminium verschaffen wollen. Weitere Informationen und Anmeldeunterlagen: RWTH International Academy: Lydia Schneider Tel.: 0241 8020 708 [email protected] GDA: Wolfgang Heidrichw Telefon: 0211 4796 271 [email protected] Metals: Energy, Emissions and the Environment Conference Tel: +49 (0)5323 9379 0 eMail: [email protected] www.gdmb.de Further information: Metal Bulletin Events Tel: +44 (0)20 7779 8989 [email protected] www.metalbulletin.com 11 to 12 February 2008, Brussels In the European metals industry, energy and climate change are high on the agenda. Both pose enormous challenges and threats, none more so than the risk of migration of European primary production. The conference will discuss key issues including: energy costs and impact on production and competitiveness, current and future regulation challenging the European metals industry, metals as innovative and sustainable materials, life-cycle developments, waste legislation and much more. Further information: Metal Bulletin Events Tel: +44 (0)20 7779 8989 [email protected] www.metalbulletin.com 8. KBU – Kolloquium zu Wirtschaft und Umweltrecht 28. bis 29. Februar 2008, Aachen Die gemeinsame Tagung des Lehr- und Forschungsgebiets Berg- und Umweltrecht der RWTH Aachen sowie der GDMB Gesellschaft für Bergbau, Metallurgie, Rohstoff- und Umwelttechnik steht unter der Thematik „10 Jahre Berg- und Umweltrecht: Habitatschutz – Mineralische Abfälle – Emissionshandel“. Im Rahmen der Entsorgung bergbaulicher Abfälle gilt es nach wie vor, die Richtlinie bergbauliche Abfälle umzusetzen. Der Emissionshandel geht nunmehr in die zweite Runde, so dass sich die Auswirkungen auf die verschiedenen Branchen deutlicher zeigen. Hinzu kommt, dass scharfe Anforderungen aus dem Habitat- und Vogelschutz bergbaulichen Projekten Probleme bereiten oder sie ganz blockieren. Hierzu werden auch Reformvorschläge präsentiert und bewertet. Weitere Infos: GDMB-Geschäftsstelle ALUMINIUM · 1-2/2008 Ferrous & Non-ferrous Scrap Metal 27 to 28 February 2008, Moscow The conference is dedicated to the issues of metal scrap recycling, price formation, and consumption in Russia and overseas. Direct networking and exchange of views will encourage the expansion of mutually beneficial cooperation between scrap metal recyclers and metallurgists. Participants are leading scrap metal collectors and recyclers, basic scrap metal consumers – steel works, tube plants, transport and logistics companies, scrap metal exporters of Russia, the CIS, and overseas. There will be arranged simultaneous translation into Russian and English. Further information: Rusmet.Ru Ltd. Tel: +7 495 980 0608 [email protected] www.lom.rusmet.ru 14th Bauxite and Alumina Seminar 3 to 5 March 2008, Miami, USA Jointly organised by Industrial Minerals and Metal Bulletin, the 14th Bauxite and Alumina seminar will provide the forum in which to examine and debate the key issues that will be influencing market dynamics for this important segment of the aluminium supply chain over the coming years. Key topics to be discussed are: alumina – latest global pressures and balances; bauxite – exploration and prospective; aluminium consolidation – impact and the implication for alumina supplies and trade flows; costs of alumina production – how to reduce the costs and maximize the production; logistics – problems and emerging trends; sustainability and environment issues – challenges ahead for the industry. LASYS – Messe für Systemlösungen in der Laser-Materialbearbeitung 4. bis 6. März 2008, Stuttgart Die weltweite Nachfrage nach Lasersystemen zur Materialbearbeitung steigt rapide an und ist Ausdruck ständig erweiterter Einsatzbereiche der Lasertechnik. Hier setzt die LASYS an: Sie zeigt Systeme und Verfahren für die ganze Palette der Bearbeitungsformen – Schweißen, Schneiden, Bohren, Löten, Beschriften u.v.m. – mit Laser. Damit ist sie Marktplatz und zugleich branchenübergreifende Kommunikationsplattform. Die Messe wendet sich an die Investitionsgüterindustrie, OEMs sowie Zulieferer. Einen Schwerpunkt der Auftaktveranstaltung bilden die Wirtschaftszweige, die den Messestandort Stuttgart prominent prägen: Automobil- und -zulieferindustrie, Maschinen- und Anlagenbau, metallbearbeitende und -verarbeitende Industrie, Medizintechnik, Feinwerkund Präzisionstechnik. Weitere Infos: Landesmesse Stuttgart GmbH Tel: +49 (0)711 2589 0 [email protected] www.messe-stuttgart.de TMS 2008 9 to 13 March 2008, New Orleans, USA When materials scientists and engineers from 70 countries gather for the TMS 2008, the focus will be on sharing research and technology to find materials solutions to some of the world’s most pressing problems. More than 2,000 papers will be presented by authors. Among the challenges they will address are: Resolving technology and techno-management issues for the pro- 103 V E R A N S TA LT U N G E N duction of aluminium, metal casting, steel, automotive and electronic materials; Stabilizing climate change and reducing greenhouse gas emissions; Optimizing energy utilization; Developing materials for high-performance applications; Achieving process improvement for a variety of materials under a variety of conditions; Preparing future materials scientists and engineers. These issues and others will be presented in 56 symposia covering the four major themes of light metals; extraction, processing, structure and properties; emerging materials; and materials and society. Further information: TMS Meetings Services 724 776 9000 [email protected] www.tms.org 3rd International Conference on High Speed Forming 11 to 13 March 2008, Dortmund, GER Objectives and topics of the ICHSF 2008 conference are: process technologies (electromagnetic, explosive and shock wave forming, combined processes), tools and equipment (tool design and manufacturing, machine design, pulsed power equipment), energy (process efficiency, emissions, life cycle analysis), materials and measurement techniques (material characteristics and behaviour, high speed testing methods, process monitoring, quality assurance), modelling and simulation (finite and boundary element method, physical modelling, analytical techniques, contact and impact modelling), industrial applications (e. g. automotive, aerospace, electrical industry, chemical industry). Further information: ICHSF 08 Tel: +49 (0)231 755 - 6917, - 5238 [email protected] www.ichsf.iul.uni-dortmund.de Euroguss und Internationaler Deutscher Druckgusstag 11. bis 13. März 2008, Nürnberg Euroguss, die internationale Fachmesse für Druckgießtechnik ist auf Erfolgskurs. Sie hat nicht nur bei Fläche und Neuausstellern im Vergleich zur Veranstaltung 2006 zugelegt, auch das Interesse der internationalen Aussteller 104 Fortbildung REACH – Das neue EU-Chemikalienrecht, 15. Februar 2008, Köln TÜV Nord Akademie, Tel: +49 (0)221 945352 0, [email protected], www.tuevnordakademie.de Schutztextilien, 19. Februar 2008, Altdorf Technische Akademie Wuppertal, Tel: +49 (0)202 7495 0, [email protected], www.taw.de Woche der Oberflächentechnik an der FH Hannover: Vorbehandeln zur Verbesserung der Haftung, 19. bis 20. Februar 2008, Hannover Weiterbildung und Technologietransfer, Tel: +49 (0)511 9296 1020, [email protected], www.fh-hannover.de Woche der Oberflächentechnik an der FH Hannover: Adhäsionsund Haftungsprüfung, 21. Februar 2008, Hannover Weiterbildung und Technologietransfer, Tel: +49 (0)511 9296 1020, [email protected], www.fh-hannover.de Produkthaftung – Risiken in Deutschland, Europa und USA, 27. bis 28. Februar 2008, Regensburg OTTI Ostbayer. Technologie-Transfer-Institut, Tel: +49 (0)941 29688 26, [email protected], www.otti.de Einführung in die Metallkunde für Ingenieure und Techniker, 4. bis 7. März 2008, Darmstadt DGM Deutsche Gesellschaft für Materialkunde e.V., Tel: +49 (0)69 75306 757, [email protected], www.dgm.de Hightech-Klebstoffe und ihre Anwendungen, 10. bis 11. März 2008, Wuppertal Technische Akademie Wuppertal, Tel: +49 (0)202 7495 0, [email protected], www.taw.de Wirtschaftliche und technologische Aspekte endkonturnaher Fertigungsverfahren, 11. bis 12. März 2008, Düsseldorf VDI-Wissensforum GmbH, Tel: +49 (0)211 6214 201, [email protected], www.vdi-wissensforum.de Vom Mitarbeiter zur Führungskraft – Kompetenz und Souveränität von Anfang an, 11. bis 12. März 2008, Berlin TÜV Nord Akademie, Tel: +49 (0)30 201774 47, [email protected], www.tuevnordakademie.de Schweißgerechtes Konstruieren, 13. bis 14. März 2008, Köln VDI-Wissensforum GmbH, Tel: +49 (0)211 6214 201, [email protected], www.vdi-wissensforum.de ist groß. Parallel zur Fachausstellung findet der 8. Internationale Deutsche Druckgusstag statt, auf dem drei Tage lang hochkarätige Vorträge gehalten werden. Der Druckgusstag wird nun auch in den Euroguss-freien Jahren in Nürnberg stattfinden. Veranstalter ist der ideelle Träger der Messe, der Verband Deutscher Druckgießereien (VDD) in Kooperation mit dem Verein Deutscher Gießereifachleute (VDG). Weitere Infos: Nürnberg Messe GmbH Tel +49 (0)911 8606 0 [email protected] www.euroguss.de ALUMINIUM · 1-2/2008 LITERATURE SERVICE Lin, Q.; Peng, D.; Li, Y.; Lin, G. A study on the hot deformability of 2519 aluminum alloy at elevated temperatures Light Metal Age, Oktober 2007, S. 46-49 The hot deformability of 2519 aluminum alloy under elevated temperatures was studied by the analysis of true stress-strain curves and observation of the deformed microstructures with an optical microscope (OM) and a transmission electron microscope (TEM). Compression tests were performed on a Gleeble-1500 thermal simulator at the deformation temperature range from 300°C to 500°C and at a strain rate range of 0.05s-1 to 25s-1. The experimental results showed that the flow stress of 2519 aluminum alloy increases with increasing strain and tends to be constant after a peak value at lower strain rates of ε<25s-1, and a dynamic recovered sub-structure was observed with TEM. The flow stress sawtooth pattern fluctuated and decreased after a peak value with increasing strain at higher strain rates of ε≥25s−1, which was associated with a dynamic recrystallization revealed by OM and TEM. Flow softening was due to dynamic precipitate coalescence and not to dynamic recrystallization at elevated temperature and lower strain rate. A hyperbolic sine relationship correlated well for fitting the flow stress as a function of strain rate, and an Arrhenius relationship related temperature and time of dynamic recrystallization. The flow stress of 2519 alloy during high temperature deformation can be determined from the ZenerHollomon parameter including the hot deformation activation energy of 2519 aluminum alloy, which was calculated to be 167.81KJ/mol from the Arrhenius equation. 6 ill., 9 sources. ALUMINIUM 1/2 (2008) Legierungen Scamans, G. Shear processing of aluminium alloy surfaces and its influence on corrosion Aluminium International Today, Juli/August 2007, S. 26-28 Surface deformation of aluminium alloys by rolling or grinding can induce corrosion beneath coated surfaces as a result of precipitation of intermetallics depleting the matrix of protective alloying elements. Al-Mn alloys are particularly susceptible in hot rolled sheet whereas Al-Mg are not, while in material subjected to grinding the Al-Mg-Si-(Cu) AA6xxx automotive alloys are susceptible. Subjecting an aluminium surface to a mechanical processing operation such as hot or cold rolling, grinding, machining or cutting transforms the surface structure. The surface microstructure is locally transformed and, if the surface shear is high enough, then a layer with an ultra-fine grain size is developed. This layer has very different optical, mechanical and electrochemical properties to the underlying bulk microstructure. These properties can be exploited or they can be used to understand why and how aluminium alloy surfaces may corrode anomalously from the bulk alloy either during testing, as mechanical abrasion is frequently used to prepare samples for electrochemical testing, or in service, particularly under paint films. 5 ill. ALUMINIUM 1/2 (2008) Werkstoffe, Korrosion Gutensohn, M.; Wagner, G.; Eifler, D. Ultraschallschweißen von Aluminiumlitzen Schweissen und Schneiden 59 (2007) 10, S. 550-554 Das Ultraschallschweißen wurde zum Fügen von Aluminiumlitzenknoten mit Querschnittsflächen von 24 und 25,8 mm2 aus zwei unterschiedlichen Litzenqualitäten eingesetzt. Das unerwünschte Anhaften der Aluminiumlitzen am Schweißwerkzeug wurde insbesondere bei erhöhten Schweißtemperaturen im Bereich der Sonotrode beobachtet. Um diese erhöhten Schweißtemperaturen zu vermeiden und somit das Anhaften am Schweißwerkzeug zu reduzieren, wurde der Schweißprozess in zwei Schritte aufgeteilt. Ferner wurden ALUMINIUM · 1-2/2008 Verschleiß reduzierende Beschichtungen auf den Sonotroden eingesetzt, die das Anhaften auch bei einstufigem Schweißprozess entscheidend reduzieren können. Es konnte gezeigt werden, dass sich das in der Kabelbaumfertigung etablierte Ultraschall-Litzenschweißen auch zur Herstellung von Aluminiumlitzenknoten eignet. 8 Bild., 8 Qu. ALUMINIUM 1/2 (2008) Verbinden Ji, J.; Jasnau, U.; Seyffarth, P. Prozessporen beim Nd:YAG-Laserstrahl-MSGHybridschweißen von Aluminiumlegierungen – Teil 2: Strategie zu ihrer Vermeidung Schweissen und Schneiden 59 (2007) 10, S. 555-560 Die Vermeidung von Prozessporen ist wichtig für die Qualitätssicherung hybridgeschweißter Verbindungen aus Aluminiumlegierungen. Der Beitrag zeigt, dass das Verhältnis von Laserstrahlleistung zu Leistung des Metall-Schutzgasschweißprozesses (MSG-Leistung) und die Schweißgeschwindigkeit wesentliche Einflussfaktoren für die Prozessporenentstehung sind. Durch eine Verknüpfung des empirischen Wissens und statistischer Verfahren wurde eine Strategie zur Vermeidung von Prozessporen mit dem definierten Beurteilungskriterium Porendurchmesser dP 0,5 mm entwickelt. Mathematisch beschreibbare prozessporenfreie Parameterfelder können angegeben werden. Mit der Porenstrategie wurde ein Diagramm für die Vorhersage der Prozessporenentstehung und die Strategie für die Parametereinstellung entwickelt. Diese Ergebnisse tragen zur Erhöhung der Schweißnahtqualität beim Laserstrahl-MSG-Hybridschweißen von Aluminiumlegierungen bei und bilden die Voraussetzung für eine Optimierung der Schweißparameter.7 Bild., 7 Qu. ALUMINIUM 1/2 (2008) Verbinden Weiss, K.; Honsel, C. Simulation von Gefüge und mechanischen Eigenschaften von Strukturbauteilen aus Magnesium Giesserei 94 11/2007, S. 30-37 Gewichtsreduktion ist ein zentrales Thema in der Automobil-, Luft- und Raumfahrtindustrie. Aufgrund der geringen Dichte von Magnesium bieten sich Magnesiumlegierungen zur effizienten Gewichtsreduzierung an. Der Beitrag erläutert das Potenzial dieser Legierungsgruppe an einem Beispiel aus der Luftfahrt. Es wird ein Modell für die Simulation lokaler mechanischer Eigenschaften von Magnesium-Gussbauteilen vorgestellt und an Testplatten für die kommerzielle Legierung AZ91E verifiziert. Des Weiteren wird das Modell auf die neu entwickelte hochfeste Legierung MRI207 erweitert. Für beide Legierungen wird das Modell auf zwei typische Gehäusebauteile des Business Jets G150 (von I.A.I. in Tel Aviv produziert) angewendet. Beide Bauteile werden den strengen Richtlinien der Luftfahrttechnik unterzogen und für flugtauglich befunden. 10 Bild., 1 Tab., 8 Qu. ALUMINIUM 1/2 (2008) Magnesium Scharf, C.; Ditze, Z. u. A.; Horny, K.; Franke, G.; Blawert, C.; Kainer, K.-U.; Morales, E. Untersuchungen zum Einsatz einer MagnesiumSekundärlegierung in der industriellen Praxis Giesserei 94 11/2007, S. 38-50 Da der Energieverbrauch im Transportwesen wegen der emittierten Treibhausgase stark zu reduzieren ist, gewinnt der Einsatz von Leichtmetallen dort immer mehr an Bedeutung. Dem steht jedoch der hohe Energiebedarf bei der Herstellung aus den primären Rohstoffen entgegen. In dieser Situation spielt das Recycling gerade bei Leichtmetallen eine wichtige Rolle, denn der hierfür erforderliche Energiebedarf macht nur 105 LITERATURSERVICE einen Bruchteil der bei der Primärgewinnung benötigten Energie aus. Beim Recycling haben jedoch Magnesiumlegierungen den Nachteil, dass es bisher keine definierten Sekundärlegierungen wie bei den Aluminiumlegierungen gibt. Die Untersuchungen des Gießverhaltens, der mechanischen Eigenschaften und der Korrosionseigenschaften der neuen Sekundärlegierung AZC1231 zeigen, dass die bisher bestehende Lücke im Recycling von Magnesiumlegierungen mit dieser Legierung geschlossen werden konnte. Es ist nunmehr möglich, sowohl Altschrott als auch durch Kupfer und Nickel verunreinigte Magnesiumlieferungen durch einfaches Umschmelzen zu recyceln. Nachteilig wirkt sich die deutlich geringere Duktilität im Vergleich zu AZ91 aus. 16 Bild., 7 Tab., 10 Qu. ALUMINIUM 1/2 (2008) Recycling Karaaslan, A.; Lus, M. Rissvermeidung bei der schmelzmetallurgischen Herstellung einer SiC-partikelverstärkten Aluminiumlegierung A6063 MP Materials Testing 49 (2007) 11-12, S. 603-605 Leichtmetall-Verbundwerkstoffe gewinnen aufgrund ihrer mechanisch-technologisch verbesserten Eigenschaften gegenüber den unverstärkten Matrixwerkstoffen zunehmend an Bedeutung. Die vorliegende Arbeit befasst sich mit der pulvermetallurgischen Herstellung eines mit Siliziumkarbid verstärkten Aluminiumpulvers. Ein besonders gutes Ergebnis wurde durch den Zusatz von 12 Volumenprozent Siliziumkarbid beobachtet. Im Rahmen der Untersuchungen wurden neben dem Volumenanteil der SiC-Teilchen auch die Gießund Formtemperatur variiert, um bei der Herstellung von Verbundwerkstoffen die Verteilung des SiC in der Metallmatrix zu optimieren. 4 Bild., 2 Tab., 7 Qu. ALUMINIUM 1/2 (2008) Pulver Ji, J.; Jasnau, U.; Seyffarth, P. Gefügeverbesserung im Schweißgut beim Nd: YAG-Laserstrahl-MSG-Hybridschweißen von Aluminiumlegierungen Schweißen und Schneiden 59 (2007) Heft 11, S. 608-612 In den bisherigen vier Teilen der Veröffentlichungsreihe standen bei der Qualitätssicherung von Nd:YAG-LaserstrahlMSG-Hybridschweißverbindungen an Aluminiumlegierungen die Nahtformparameter, die Porenfreiheit und die Gewährleistung der geforderten Einbrandtiefe im Zentrum. Da das Hybridschweißen eine veränderte Wärmeeinbringung gegenüber dem reinen Laserschweißen mit sich bringt, ist die Frage der Gefügebeeinflussung ebenfalls von Interesse für die Optimierung der Nahteigenschaften. Insbesondere ist zu untersuchen, inwieweit beim Laserstrahlhybridschweißen eine unzulässige Kornvergröberung auftritt. 7 Bild., 10 Qu. ALUMINIUM 1/2 (2008) Verbinden Dragulin, D.; Franke, R.; Hoffmann, O.; Fischer, D.; Dragulin, M. Aluminium-Druckgusslegierung: Praktische Aspekte des thermomechanischen Verhaltens der AlSi10MnMg Druckgusspraxis 7/2007, S. 274-278 Die Legierung AlSi10MnMg weist ausgesprochen gute mechanische Eigenschaften, insbesondere Dehnung, im T7-Zustand auf und ist dadurch eine optimale Lösung für viele Strukturteile, die durch den Druckgussprozess hergestellt werden können. Zu dieser Klasse gehört die Legierung Silafont-36 von Aluminium Rheinfelden, die höhere Werte als eine StandardAlSi10MnMg erreicht. Particular physical properties and certain thermo-physical processes have been examined for the predominantly utilised pressure die-casting alloy – AlSi10MnMg, as used in 106 the car industry. As a result, an in-depth study was carried out, which chiefly concentrated upon the thermo-elastic effect of this alloy, and upon its thermal effect in its zone of plasticity, as well as the elastic energy generated during deformation within this elasticity band. The study also entailed in-depth analysis of its modulus with respect to tough show that the alloy – AlSi10MnMg – features an outstanding array of physical properties (especially with elongation in the T7 state) and therefore provides an optimum solution for many structural components, which can be produced by way of the pressure die-casting process. The alloy – Silafont-36 – produced by Aluminium Rheinfelden, which attains even greater values than those provided by using standard AlSi10MnMg, belongs to this calssification. 8 Bild., 2 Tab., 2 Qu. ALUMINIUM 1/2 (2008) Werkstoffe, Metallkunde Modulares Druckgusskonzept für leichte AluminiumZylinderkurbelgehäuse Automotive Materials, 6/2007, S. 24-26 Für die kostengünstige Herstellung von Zylinderkurbelgehäusen aus Aluminium bietet sich der Druckguss an. Das Verfahren beschränkt sich bisher auf die Open-Deck-Bauweise einschließlich der damit bauartbedingt gegebenen geringeren Steifigkeit. Einen interessanten Lösungsansatz für „Downsizing“-Motoren präsentiert die KS Aluminium-Technologie AG mit ihrem hoch flexiblen, serienfähigen „modularen Druckgusskonzept“. Hierbei kompensieren einzelne Konzeptbausteine prinzipbedingte Nachteile des herkömmlichen Druckgusses. Das Konzept ist generell geeignet, sehr große Mengen hochwertiger Al-Zylinderkurbelgehäuse darzustellen. ALUMINIUM 1/2 (2008) Druckguss Zak, O.; Zak, H.; Tonn, B. Einsatz von rasch erstarrten Vorlegierungen zur Feinung des Primärsiliziums übereutektischer AlSi17Cu4MgLegierung Druckgusspraxis 7/2007, S. 303-308 Die im Rahmen dieser Arbeit gewonnenen neuen Erkenntnisse zeigen, dass definierte Zusätze an Zirkonium ein enormes Potenzial für die Weiterentwicklung von AlSi-Standardlegierungen besitzen. In Versuchen mit der technischen Legierung AlSi17Cu4Mg konnte die Größe der Primärsiliziumkristalle von 40-50 μm (Stand der Technik) auf 18 μm reduziert werden. Dieser Effekt wurde erreicht, indem die feinende Wirkung des Phosphors durch gezielte Zugabe des Zirkoniums, welches in Form einer schnell erstarrten Vorlegierung AlZr1,3 zum Einsatz kam, unterstützt wurde. Die Vorlegierung AlZr1,3 wurde an einer vertikalen Stranggießanlage mit einer Abkühlungsgeschwindigkeit von etwa 500 bis 600 K/s hergestellt und erfordert dank feiner Gefügeausbildung und hohen Anteilen an in Aluminium-Matrix gelöstem Zirkonium beim Einsatz keine Überhitzung der Schmelze und keine längere Haltezeiten. Durch kombinierte Zirkonium-und Phosphorzugabe konnte bei einem Phosphorgehalt von 100 ppm zusätzlich zur Feinung des Primärsiliziums ein lamellares AlSi-Eutektikum und damit eine deutliche Verbesserung der Festigkeitseigenschaften im Gusszustand um 35 Prozent erzielt werden, die bei der Standardlegierung AlSi17Cu4Mg erst nach der Wärmebehandlung T6 erreicht werden können. New possibilities in influencing the micro-structure of hypereutectic AlSi17Cu4Mg, used for pistons and engine blocks, are presented in this report, so that this material can meet the increased demands imposed by the automobile industry. The basic concept for the examinations, which were conducted for this purpose, focused upon the fact that the smelts are to be treated by means of rapidly solidifying AISi14- and AlZr1 hardening alloys, and that the effect of these hardening alloys upon the primary silicon phase needed to be examined individually as well as jointly in conjunction with phospho- ALUMINIUM · 1-2/2008 LITERATURE SERVICE rus. It shows that the hardening alloys that were utilised, the microstructures of which deviate considerably from those of the bulk alloy materials, effect a notable refinement of the primary silicon in the AlSi17Cu4Mg alloy. It was discovered that upon adding the rapidly solidifying AlZr1,3 alloy, together with phosphorus, a particularly marked effect was able to be accomplished upon the primary silicon, and as a consequence of this, has proven to have had an effect upon the physical properties of the AlSi17Cu4Mg alloy, even in the state when it is cast. The same comparable level of physical properties can only be attained for “standard” alloy after T6 heat treatment has been carried out. 7 ill., 3 tables., 19 sources. ALUMINIUM 1/2 (2008) Werkstoffe Blauel, J. G.; Pfeiffer, W.; Varfolomeyev, I.; Veneziano, C. Bruchmechanische Bewertung von rissbehafteten Schweißkonstruktionen mit Eigenspannungen MP Materials Testing 49 (2007) 11-12, S. 577-587 Die Anwendung bruchmechanischer Konzepte bei der Festigkeitsbewertung von Schweißkonstruktionen erlaubt prinzipiell neben den werkstoffspezifischen Effekten auch die Wirkung von Eigenspannungen auf vorhandene Imperfektionen quantitativ zu erfassen. Mögliche Vorgehensweisen bei den dafür durchzuführenden Einzelschritten – Eigenspannungsermittlung, Beanspruchungsanalyse, Kennwertermittlung und Versagensbewertung – werden beschrieben und anhand von Beispielen demonstriert. 22 Bild., 23 Qu. ALUMINIUM 1/2 (2008) Verbinden Sölter, J.; Reucher, G. Werkstoffeinfluss auf die Spanbildung bei hohen Schnittgeschwindigkeiten MM Maschinenmarkt 43/2007, S. 46-51 Die Spanbildung und die Abhängigkeit der Prozesskräfte von der Schnittgeschwindigkeit werden stark durch den Werkstoff und den Wärmebehandlungszustand des Werkstücks beeinflusst. Außer thermischen und mechanischen Werkstoffeigenschaften entscheiden die Mikrostruktur und die chemische Zusammensetzung des Werkstoffs, ob eine Spansegmentierung bei hohen Schnittgeschwindigkeiten einsetzt. 5 Bild, 7 Qu. ALUMINIUM 1/2 (2008) Umformen Eder, Chr. Thixocasting für komplexe Geometrien – Lösungen aus einem Guss Automotive Materials, 6/2007, S. 36-37 Aufgrund des steigenden Kostendrucks streben Automobilund Nutzfahrzeughersteller Lösungen an, bei denen sich komplexe Geometrien in Net-Shape-Qualität ohne nachfolgende mechanische Bearbeitung realisieren lassen. Hierbei bietet sich das Thixocasting der österreichischen SAG Thixalloy Components an. Kriterien für Thixocasting-Anwendungen sind: keine Teile mit geringen Qualitätsanforderungen, große Unterschiede in den Wanddicken realisierbar, hohe Komplexität der Konstruktion und Integration von Funktionen, Druckdichtigkeit durch porenarme Qualität, thermische Behandlungen – hohe Schweißeignung, Wärmebehandlung, hohe Anforderungen an die Oberfläche, Thixocasting kann besonders Prozesse wie mechanische Bearbeitung, Schmieden, Feinguss, Kokillenguss, Vakuum-Druckguss substituieren, Ersatz von gefügten Blech- und Strangpressteilen durch Integration. ALUMINIUM 1/2 (2008) Formguss Schleich, R.; Papaioanu, A.; Liewald, M. Karosserieblech sicher biegen Blech, Rohre, Profile 11/2007, S. 22-23 Mechanische Werkstoffkennwerte sind in der Umformtechnik ein etabliertes Mittel zur Qualitätssicherung. Für biegedominierte Verfahren scheinen die konventionellen Kennwerte unzureichend. Am Institut für Umformtechnik (IFU ) in Stuttgart wird deshalb ein Prüfverfahren entwickelt, das mit einer falzprozessnahen Kinematik und den relevanten Spannungszuständen operiert. 4 Bild. ALUMINIUM 1/2 (2008) Umformen Aluminium Oxid Stade – Auch nach 35 Jahren eine der effizientesten Oxidfabriken in der Welt Aluminium 83 (2007) 12, S. 26-31 Seit 1973 verarbeitet die Aluminium Oxid Stade GmbH Bauxit zu Aluminiumoxid. Ursprünglich auf die Produktion von Oxid für die Aluminiumelektrolyse ausgelegt, hat sich AOS längst auf die Herstellung von chemischem Oxid und von Hydroxidprodukten fokussiert. Noch immer zählt AOS zu den technisch und energetisch effizientesten Oxidfabriken in der Welt. 2007 wird erstmals die Produktion von 1 Mio. Tonnen erreicht. Von den sechs in Europa produzierenden Oxidfabriken ist AOS bei chemischen Produkten die Nummer 1. Der Beitrag geht auf die anlagentechnischen Besonderheiten ein, mit denen sich AOS vom Wettbewerb abhebt. Artikel dt./engl. 4 Fotos. ALUMINIUM 1/2 (2008) Gewinnung Trommer, G. Moderne Verfahren zum Schweißen von Aluminium Viele Wege führen zum Ziel Aluminium 83 (2007) 12, S. 34-39 Das Fügeverfahren Schweißen spielt für den Konstruktionswerkstoff Aluminium eine dominierende Rolle. Von besonderer Bedeutung sind Anwendungen des Maschinen- und Apparatebaus, im Verkehrswesen sowie im Bauwesen. Beim Schweißen von Aluminium sind, im Vergleich zu Stahl, jedoch einige Besonderheiten zu beachten. Sie hängen primär mit den Werkstoffeigenschaften des Leichtmetalls zusammen. Der Beitrag zeigt Zusammenhänge und Lösungen für Schweißverbindungen auf. Die Spannbreite der Ausführungen reicht vom Elektroden-Handschweißen über das WIG-, Orbital-, Plasma-, MIG-, CMT-, Laser-MSG-Lichtbogen-Schweißen bis hin zum Widerstands-Punktschweißen „DeltaSpot“. 6 Fotos. ALUMINIUM 1/2 (2008) Schweißen Für Schrifttum zum Thema „Aluminium“ ist der Gesamtverband der Aluminiumindustrie e.V. (GDA) der kompetente Ansprechpartner. Die hier referierten Beiträge repräsentieren lediglich einen Ausschnitt aus dem umfassenden aktuellen Bestand der GDA-Bibliothek. Die von der Aluminium-Zentrale seit den dreißiger Jahren kontinuierlich aufgebaute Fach-Bibliothek wird duch den GDA weitergeführt, ausgebaut und auf die neuen Medien umgestellt. Sie steht allen Interessenten offen. Ansprechpartner ist Dr. Karsten Hein, E-Mail: [email protected] ALUMINIUM · 1-2/2008 107 PAT E N T E Patentblatt November 2007 Al-Si-Lotlegierungen und Ihre Verwendung für das Hartlöten von Aluminium und Aluminium/Stahl-Fügungen. Umicore AG & Co. KG, 63457 Hanau, DE. (B23K 35/28, EPA 1842619, EP-AT: 10.04.2007) Neue Al-Cu-Li-Mg-Ag-Mn-Zr-Legierung für Bauanwendungen, die hohe Festigkeit und hohe Bruchzähigkeit erfordern. Alcan Rolled Products Ravenswood LLC, Ravenswood, W.Va., US. (C22C 21/12, EPA 1641953, EP-AT: 26.05.2004) Dünne Bänder oder Bleche aus einer AlFe-Si-Legierung. Novelis,Inc., Toronto, Ontario, CA. (C22C 1/00, PS 60 2004 005 045, EP 1644545, EP-AT: 19.07.2004) Verfahren zum Tiefziehen von Teilen aus Al-Mg-Legierungen. Alcan Rhenalu, Paris, FR. (B21D 22/20, EP 1601478, EPAT: 24.02.2004) Grobblech oder stranggepresstes Teil aus Aluminium-Magnesium-Legierung. Aleris Aluminium Koblenz GmbH, 56070 Koblenz, DE. (C22C 21/06, PS 697 03 441, EP 0892858, EP-AT: 27.03.1997) Kohlenwasserstoffumwandlungsverfahren unter Verwendung einer Aluminium und ein zweiwertiges Metall enthaltenden Katalysatorzusammensetzung. Albemarle Netherlands B.V., Amersfoort, NL. (B01J 21/16, ) EPA 1838436, EP-AT: 19.11.2005) Aluminium-Gusslegierung. EADS Deutschland GmbH, 85521 Ottobrunn, DE; Aluminium Rheinfelden GmbH, 79618 Rheinfelden, DE. (C22C 21/06, PS 103 52 932, AT: 11.11.2003) Wärmebehandlung von Druckgussstücken aus Aluminiumlegierung. Commonwealth Scientific and Industrial Research Organisation, Campbell, AU. (C22F 1/04, EPA 1844174, EP-AT: 19.12.2005) In einem Aluminium-Gussteil einzugießender Grauguss-Rohling und entsprechendes Gussverfahren. Audi AG, 85057 Ingolstadt, DE. (F02F 1/00, OS 198 36 706, AT: 13.08.1998) Aluminiumlegierung für Gussteil. Dr.Ing. h.c. F. Porsche AG, 70435 Stuttgart, DE. (C22C 21/02, EPA 1840233, EP-AT: 12.12.2006) Behandeln von Abstandhaltern in gestapelten Aluminium-Blöcken. Alcoa Inc., Pittsburgh, Pa., US. (C21D 1/70, PS 601 23 737, EP 1215289, EP-AT: 11.12.2001) Verfahren zum Hartlöten einer Aluminium-Magnesium-Legierung mit einem Kalium-Fluorozinkat enthaltenden Flussmittel. Denso Corp., Kariya, Aichi, JP; Sumitomo Light Metal Industries, Ltd., Tokio/Tokyo, JP. (B23K 1/00, PS 60 2004 004 428, EP 1466691, EP-AT: 31.03.2004) Randspannungsentlastung von Grobblech aus Aluminium. Alcan Rhenalu, Paris, FR. (C22F 1/00, PS 603 12 373, EP 1567685, EP-AT: 04.12.2003) Wärmebehandlungsverfahren für Blech aus Aluminium-Legierung. Novelis, Inc., Toronto, Ontario, CA. (C22F 1/05, PS 695 20 007, EP 0805879, EP-AT: 05.09.1995) Hochfestes Blech aus Al-Zn-Cu-Mg-Legierung mit geringen inneren Spannungen. Alcan Rhenalu, Paris, FR. (C22F 1/053, EPA 1838891, EP-AT: 09.12.2005) Verfahren zum Auswechseln einer Anode in einer Zelle zur elektrolytischen Herstellung von Aluminium mit Einstellung der Position der Anode und Wartungsvorrichtung dafür. E.C.L., Ronchin, FR. (C25C 3/06, EPA 1838901, EP-AT: 12.10.2005) Endloskapillarrohr in Aluminiumlegierung, Drosselventil mit diesem Endloskapillarrohr in Aluminiumlegierung und Aluminiumlegierung. Aro Tubi Trafilerie S.p.A., Milano, IT; C.R. S.r.l., Moniga Del Garda, IT. (F25B 41/06, EPA 1840487, EP-AT: 31.03.2006) Verfahren und Vorrichtung zum Vorbereiten eines Bauteils aus oberflächlich oxidierendem Metall, insbesondere aus Aluminium, zum Schweißen oder Kleben. SLE Electronic GmbH, 94481 Grafenau, DE. (B08B 3/00, PS 10 2006 009 993, AT: 03.03.2006) 6xxx-Aluminiumlegierung. Comalco Aluminium Ltd., Melbourne, Victoria, AU. (C22C 21/02, EPA 1840234, EP-AT: 04.07.1997) Vorrichtung und Verfahren zur Sicherung von als Paket gelagerten Aluminium-Stranggussprodukten, so genannten Masseln, zu Transportzwecken. Signode System GmbH, 46535 Dinslaken, DE. (B65D 85/62, PS 10 2006 038 996, AT: 21.08.2006) Gummibauteil mit Metallkomponente auf Basis von Aluminium und Verfahren zum Herstellen desselben. Tokai Rubber Industries, Ltd., Komaki, Aichi, JP. (C23C 30/00, OS 10 2007 020 030, AT: 27.04.2007) 108 Platte aus einer Aluminiumlegierung und Herstellungsverfahren dafür. Kabushiki Kaisha Kobe Seiko Sho, Kobe, Hyogo, JP. (C22C 21/06, EPA 1842935, EP-AT: 13.01.2006) Lötmaterial für Aluminiumlegierung. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (B23K 35/28, EPA 1843872, EP-AT: 10.01.2006) Abschreckunempfindliche Aluminiumlegierung sowie Verfahren zum Herstellen eines Halbzeuges aus dieser Legierung. Otto Fuchs KG, 58540 Meinerzhagen, DE. (C22C 21/10, EP 1 683 882, EP-AT: 21.11.2005) Anodisierende Aluminiumlegierung. Short Brothers PLC, Belfast, Nordirland, GB. (C25D 11/12, EPA 1836331, EP-AT: 10.01.2006) Partikelverstärkte Magnesium- oder Aluminiumlegierung. Bayerische Motoren Werke AG, 80809 München, DE. (C22C 49/04, OS 10 2006 023 041, AT: 17.05.2006) Aluminiumlegierung, Verbindungs- und Halteeinrichtung für Glaskonstruktionsvorhaben. Ting, Jen-Chieh, Kaohsiung City, TW. (E04B 1/38, GM 20 2007 009 426, AT: 05.07.2007) Warmfeste Aluminiumlegierung. Aluminium Rheinfelden GmbH, 79618 Rheinfelden, DE. (C22C 21/08, EP 1 757 709, EP-AT: 28.02.2006) Druckgusserzeugnis aus Aluminiumlegierung. Corus Aluminium Voerde GmbH, 46562 Voerde, DE; Corus Aluminium Walzprodukte GmbH, 56070 Koblenz, DE. (C22C 21/06, PS 601 26 529, EP 1138794, EP-AT: 15.03.2001) Aluminiumlegierung geeignet für Bleche und ein Verfahren zu deren Herstellung. Furukawa-Sky Aluminum Corp., Tokio/ Tokyo, JP; Honda Giken Kogyo K.K., Tokyo, JP. (C22C 21/00, PS 602 15 579, EP 1260600, EP-AT: 15.05.2002) Wärmetauscher. Showa Denko K.K., Minato-ku, Tokyo, JP. (F28F 9/02, WO 2006 059783, WO-AT: 30.11.2005) Vorrichtung zur Fertigung von aus Leichtmetall gefertigten Holmen eines Rahmens und/oder eines Flügels eines Fensters. Aug. Winkhaus GmbH & Co. KG, 48291 Telgte, DE. (B21D 53/74, EPA 1839770, EP-AT: 22.12.2006) Kühlkokille zum Vergießen von Leichtmetall-Gusswerkstoffen und Verwendung einer solchen Kokille sowie eines Gusseisenwerkstoffs. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B22C 9706, EPA 1841554, EP-AT: 27.01.2006) Verfahren zum Gießen von Bauteilen aus Leichtmetall nach dem Kippgießprinzip. Rautenbach-Guß Wernigerode GmbH, 38855 Wernigerode, DE. (B22D 23/00, EP 1 742 752, EP-AT: 30.03.2005) ALUMINIUM · 1-2/2008 PAT E N T E Verbundmaterial aus Leichtmetall und mit Kohlenstofffasern verstärktem Kunststoff. Toray Industries, Inc., Tokio/ Tokyo, JP. (B32B 15/08, PS 698 36 259, EP 0938969, EP-AT: 20.08.1998) Anordnung zur Bildung einer Kreuzverbindung zwischen einem Längspfosten und einem Querpfosten bei einem Fenster oder einer Türe aus Kunststoff oder Leichtmetall. PHI Technik für Fenster und Türen GmbH, 91459 Markt Erlbach, DE. (E06B 3/964, GM 299 14 966, AT: 26.08.1999) Magnesiumlegierungen für die Wasserstoffspeicherung. The University of Queensland, Santa Lucia, Queensland, AU. (C22C 23/00, EPA EP 1838887, EPAT: 02.12.2005) Hochfeste Legierung auf Aluminiumbasis und ein daraus hergestelltes Produkt. Federalnoe Gosudarstvatelsky Institut Unitarnoe Predpriyatie “Vserossiisky Nauchno-Issledovatelsky Institut Aviatsionnykh Materialov”, Moskau/Moscow, RU; Otkrytoe Aktsionernoe Obschestvo “Samarsky Metallurgichesky Zavod”, Samara, RU. (C22C 21/10, PS 601 20 987, EP 1306455, EP-AT: 25.07.2001) Aus mindestens zwei vorgegossenen Abschnitten zusammengesetztes Bauteil und Verfahren zu seiner Herstellung. Hydro Aluminium Mandl&Berger GmbH, Linz, AT. (B22D 19/04, OS 10 2005 059 309, AT: 09.12.2005) Profil aus einem Leichtmetallwerkstoff mit an diesem verlaufenden Rohrelementen. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH.(E04D 3/30, GM 20 2007 008 488, AT: 13.06.2007) Verfahren zur Herstellung von Aluminiumverbundwerkstoff. Aluminium Core Technology Co., Ltd., Tokyo, JP; Nippon Light Metal Co. Ltd., Tokio/Tokyo, JP. (B22F 3/24, EPA 1837103, EP-AT: 28.12.2005) Verfahren zur Herstellung von grobkörnigem Aluminiumhydroxyd. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH. (C01F 7/14, PS 698 36 962, EP 0997435, EP-AT: 28.10.1998) Dachreling sowie Verfahren zur Herstellung einer solchen Dachreling. WKW Erbslöh Automotive GmbH, 42349 Wuppertal, DE. (B60R 9/04, OS 10 2006 025 933, AT: 10.05.2006) Inerte Cermet-Anode zur Verwendung in der elektrolytischen Herstellung von Metallen. Alcoa Inc., Pittsburgh, Pa., US. (C25C 3/12, PS 600 33 837, EP 1226287, EP-AT: 27.10.2000) Magnesiumlegierung und dazugehöriges Herstellungsverfahren. Biotronik VI Patent AG, Baar, CH. (C22C 23/04, EPA 1840235, EP-AT: 22.03.2007) Gießform, Vorrichtung und Verfahren zum Vergießen von Metallschmelze. Hydro Aluminium Alucast GmbH, 66763 Dillingen, DE. (B22C 9/08, PS 10 2005 010 838, AT: 07.03.2005) Wärmetauscherprofil. Erbslöh Aluminium GmbH, 42553 Velbert, DE. (F28F 1/02, EPA 1840494, EP-AT: 23.03.2007) Verfahren und Stellgliedvorrichtung. Norsk Hydro ASA, Oslo, NO. (E21B 43/32, EP 1 718 842, EP-AT: 11.02.2005) Funktionale Direktbeschichtung einer Aluminiumfolie. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B21C 47/26, EPA 1837091, EP-AT: 09.03.2007) Verbundprofil mit einem Tragkörper aus Leichtmetallwerkstoff sowie einem Profilband und Verfahren zum Herstellen des Verbundprofils. Alcan Technology & Management Ltd., Neuhausen am Rheinfall, CH. (B60M 1/30 und B21K 9/00, OS 10 2005 063 436 und PS 10 2005 004 547 und EPA 1843866, AT: 31.01.2005 und EP-AT: 20.12.2005) Wasserkühlsystem für eine Stranggießvorrichtung. Norsk Hydro ASA, Oslo/ Osló, NO. (B22D 11/049, PS 601 24 031, EP 1157765, EP-AT: 14.05.2001) Wärmetauscher. Showa Denko K.K., Tokio/Tokyo, JP. (F28D 1/053, WO 2006 070923, WO-AT: 27.12.2005) Aluminiummaterial für eine Elektrode eines elektrolytischen Kondensators, Verfahren zur Herstellung von Elektrodenmaterial für einen elektrolytischen Kondensator, Anodenmaterial für einen elektrolytischen Aluminiumkondensator und elektrolytischer Aluminiumkondensator. Showa Denko K.K., Tokio/Tokyo, JP. (C22C 21/00, EPA 1841892, EP-AT: 21.12.2005) Verpackungsbeutel mit Umverpackung. Alcan Technology & Management Ltd., Neuhausen am Rheinfall, CH. (B65D 33/02, EPA 1714892, EP-AT: 24.11.2005) Profilelement zum Befestigen einer Stoßstange an Längsträgern eines Fahrzeuges sowie Verfahren dazu. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH. (B60R 19/34, OS 10 2006 019 654, AT: 25.04.2006 Schlauchförmiges Glied mit einem aus mehreren Metalldrähten oder -Röhren bestehenden Umfang. Norsk Hydro ASA, Oslo, NO. (F16L 11/14, EP 1 563 215, EP-AT: 27.10.2003) ALUMINIUM · 1-2/2008 Flexibles Rohr oder flexibler Schlauch. Alcan Deutschland GmbH, 37075 Göttingen, DE. (F16L 59/153, PS 502 08 527, EP 1286102, EP-AT: 14.08.2002) Einrichtung und Verfahren zur Sammlung der Abflüsse einer Elektrolysezelle. Aluminium Pechiney, Voreppe, FR. (C25C 3/22, EPA 1845175, EP-AT: 11.04.2006) Schaltungsanordnung zum Steuern eines Krustenbrechers. VAW Aluminium-Technologie GmbH, 53117 Bonn, DE. (C25C 3/20, GM 299 10 803, AT: 21.06.1999) Verfahren zum Gießen eines Artikels. Mahle Powertrain Ltd., St. James, Northampton, GB. (B22C 9/02, EPA 1841553, EP-AT: 08.12.2005) Innere Rohrprüfvorrichtung und Verfahren. Norsk Elektro Optikk AS, Skarer, NO. (F16L 55/26, PS 603 11 977, EP 1497585, EP-AT: 04.04.2003) Aluminiumlagerlegierungsteil. Daido Metal Co. Ltd., Nagoya, Aichi, JP. (C22C 21/00, PS 101 35 895, AT: 24.07.2001) Patentblatt Dezember 2007 Verfahren zum MIG Schweißen von AlLegierungen mit Ar/He/O2-Schutzgas. L‘Air Liquide Société Anonyme pour l‘Etude et l‘Exploitation des Procédés Georges Claude, Paris, Cedex, FR. (B23K 9/16, EP 1 166 940, EP-AT: 11.06.2001 Druckgießen von Aluminium. Commonwealth Scientific and Industrial Research Organisation, Campbell, AU: (B22D 17/20, PS 601 28 114, EP 1320434, EPAT: 24.08.2001) Verfahren zum Aufbringen einer Beschichtung auf überlappten Oberflächen von Bauelementen aus Aluminium-Legierung sowie derart beschichtete überlappte Oberflächen. McDonnell Douglas Corp., Seal Beach, Calif., US. (C22F 1/04, PS 699 35 480, EP 0985737, EP-AT: 25.08.1999) Aluminium-Zink-Magnesium-ScandiumLegierungen und Herstellungsverfahren dafür. Langan, Timothy, Catonsville, Md., US. (C22C 21/10, EPA 1848835, EP-AT: 01.02.2006) Neue Fe-Al-Legierung und Herstellungsverfahren dafür. Okanda, Yoshihira, Nishinomiya, JP. (C21D 9/46, EPA 1847624, EP-AT: 10.02.2006) Verfahren unter Verwendung von ausgewählten Kohlen zur Reaktion © 109 PAT E N T E mit Al2O- und Al-Dämpfen bei der carbothermischen Produktion von Aluminium. Alcoa Inc., Pittsburgh, Pa., US; Elkem AS, Oslo, NO; Carnegie Mellon University, Pittsburgh, Pa., US. (C22B 21/02, EP 1 689 895, EP-AT: 02.12.2004) Verfahren zum Diffusionsfügen von Magnesium/Aluminium-Bauteilen. General Motors Corp., Detroit, Mich., US. (B23K 35/28, PS 602 16 369, EP 1273385, EPAT: 08.05.2002) Verbindung von Profilen, insbesondere Aluminium-Strangpressprofilen im Fahrzeugbau. Siemens AG, 80333 München, DE. (F16B 5/00, EPA 1688626, EP-AT: 09.01.2006) Verfahren zum Versiegeln von mit Phosphorsäure anodisiertem Aluminium. The United States of America as represented by the Secretary of the Navy, Lilj Patuxent River, Md., US. (C23C 22/05, EPA 1853750, EP-AT: 14.11.2005) Verbundblech aus Aluminium. Aleris Aluminium Duffel BVBA, Duffel, BE. (B32B 15/01, EPA 1852251, EP-AT: 02.05.2006) Metallisierung integrierter Schaltungen unter Verwendung einer Titan-Aluminium-Legierung. Micron Technology, Inc., Boise, Id., US. (H01L 23/532, OS 101 52 913, AT: 26.10.2001) Verbundwerkstoff aus einer hochfesten Aluminiumlegierung. Visteon Global Technologies, Inc., Dearborn, Mich., US. (C22C 21/04, PS 10 2004 033 457, AT: 05.07.2004) Drehtrommelofen zum Umschmelzen von Aluminium. Metallhüttenwerke Bruch GmbH, 44145 Dortmund, DE. (F27B 7/20, GM 20 2004 004 478, AT: 19.03.2004) Aluminiumhaltige Fällungskieselsäure mit einstellbarem BET/CTAB-Verhältnis. Evonik Degussa GmbH, 40474 Düsseldorf, DE. (C01B 33/193, PS 503 02 199, EP 1513768, EP-AT: 07.06.2003) Vorrichtung und Drehsicherung von Dosenenden in einem Downstaker und entsprechendes Verfahren. Alcoa Inc., Pittsburgh, Pa., US. (B65D 1/00, PS 603 13 345, EP 1545987, EP-AT: 05.08.2003) Vorrichtung zum Entwässern der Rahmenstöße einer Vorhangfassade. Norsk Hydro ASA, Oslo, NO. (E04B 2/88, EPA 1849928, EP-AT: 13.02.2007) Oberflächenbehandlungsmittel und Verfahren zum Entfernen der beim Ätzen von Druckgussteilen aus Aluminium anfallenden Si-Komponente und reduzierten Metallsalze. Jeonyoung Co., Ltd., Ansan, Kyounggi, KR. (C11D 7/18, PS 602 16 291, EP 1421164, EP-AT: 25.07.2002) Verfahren zum Sintern von Aluminiumund Aluminiumlegierungsteilen. Ex One Corp., Irwin, Pa., US. (C22C 1/04, EP 1 694 875, EP-AT: 01.12.2003) Aluminium-Elektrolytkondensator und Herstellungsverfahren. Matsushita Electric Industrial Co., Ltd., Kadoma, Osaka, JP. (H01G 9/008, PS 699 34 063, EP 0986078, EP-AT: 03.09.1999) Titan-Aluminium-Mischoxidpulver. Evonik Degussa GmbH, 40474 Düsseldorf, DE. (C01G 25/02, OS 10 2004 061 702 und OS 10 2004 061 703 und OS 10 2004 062 104, AT: 22.12.2004 und AT: 23.12.2004) Verfahren zur Herstellung von anorganisch gebundenen Formen und Kernen für Gießereizwecke, insbesondere für das Leichtmetall-Gießen. Otto-von-Guericke-Universität Magdeburg, 39106 Magdeburg, DE. (B22C 1/18, OS 10 2006 026 796, AT: 07.06.2006) Stabilisiertes Aluminium-Zirkon-Mischoxidpulver. Evonik Degussa GmbH, 40474 Düsseldorf, DE. (C01G 1/02, OS 10 2005 040 156, AT: 25.08.2005) Verpackungsbeutel. Alcan Technology & Management Ltd., Neuhausen am Rheinfall, CH. (B65D 33/02, EPA 1854732, EPAT: 12.05.2006) Profilsystem, Halter und Verfahren zur Befestigung für und Austausch von SGVerglasung (Structural Glazing) von der Rauminnenseite für Aluminium-GlasFassaden und andere SG-Metall-GlasFassaden. inotec Engineering GmbH, 74532 Ilshofen, DE. (E04B 2/96, OS 10 2006 026 283, AT: 02.06.2006) Verfahren zur Herstellung von Verpackungsbeuteln. Alcan Technology & Management Ltd., Neuhausen am Rheinfall, CH. (B65D 75/50, EP 1 547 935, EP-AT: 23.12.2003) Durchsichtige Aluminium-Titanoxid-Beschichtung und / oder AluminiumoxidBeschichtung mit einer Rutilstruktur. Philips Intellectual Property & Standards GmbH, 20099 Hamburg, DE. (C03C 17/24, PS 60 2004 005 571, EP 1590305, EP-AT: 21.01.2004) 110 Verfahren zum Abtrennen von Abfallschichten von plattierten Bändern durch Walzplattieren. Alcan Rhenalu, Paris, FR. (B21B 47/04, PS 60 2004 003 371, EP 1628786, EP-AT: 01.06.2004) Vorrichtung und Verfahren zum Aufbringen von Sprühpumpen und dergleichen auf Behälter und zum Verschließen derselben. Alcoa Deutschland GmbH, 67547 Worms, DE. (B65B 7/28, EP 1 761 434, EP-AT: 20.06.2005) Profilverbindung, insbesondere für Aluminium-Leichtbau. Philippi, Gerd, 66793 Saarwellingen, DE. (F16B 7/00, GM 20 2004 013 726, AT: 03.09.2004) Vakuumhartlötverfahren für Aluminium. Denso Corp., Kariya, Aichi, JP. (F27B 5/05, PS 4404263, AT:10.02.1994) Verfahren zum Biegen eines bahnförmigen Stehfalzprofilbleches und Einrichtung zur Durchführung dieses Verfahrens. Corus Bausysteme GmbH, 56070 Koblenz, DE. (B21D 7/08, EP 1 631 399, EP-AT: 07.05.2004) Verfahren zur Herstellung eines halbfesten Thixogießmaterials. Honda Giken Kogyo K.K., Tokyo, JP. (C21D 1/32, PS 697 37 048, EP 1460138, EP-AT: 02.09.1997) Verfahren zur Herstellung eines Behälters aus Aluminiumblechen. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B21D 51/18, OS 10 2006 026 828, AT: 07.06.2006) Verfahren und Vorrichtung zur Herstellung eines Sandwichpaneels und nach diesem Verfahren hergestelltes Sandwichpaneel. Corus Technology BV, IJmuiden, NL. (E04 2/292, EP 1 233 114, EP-AT: 08.02.2002) Vorrichtung zum Fügen von mindestens zwei Bauteilen aus artverschiedenen Werkstoffen mit einem mit mindestens einem als Schneide ausgebildeten Formelement aufweisenden Stift. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B23K 20/12, EPA 1849552, EP-AT: 27.04.2006) Fortsetzung der Dezember-Auswertung in der nächsten Ausgabe der ALUMINIUM. ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige, den Werkstoff Aluminium betreffende Patente. Die ausführlichen Patentblätter und auch weiterführende Informationen dazu stehen der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen bei der Mitteldeutschen Informations-, Patent-, Online-Service GmbH (mipo), Julius-Ebeling-Str. 6, D-06112 Halle an der Saale, Tel. 0345/29398-0 Fax 0345/29398-40, www.mipo.de Die Gesellschaft bietet darüber hinaus weitere „Patent“-Dienstleistungen an. 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LIEFERVERZEICHNIS 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 Smelting technology Hüttentechnik Raw materials Storage facilities for smelting Anode production Anode rodding Casthouse (foundry) Casting machines Current supply Electrolysis cell (pot) Potroom Laboratory Emptying the cathode shell Cathode repair shop Second-hand plant Aluminium alloys Storage and transport 1.1 Raw Materials Rohstoffe Raw Materials Rohstoffe 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 Rohstoffe Lagermöglichkeiten in der Hütte Anodenherstellung Anodenschlägerei Gießerei Gießmaschinen Stromversorgung Elektrolyseofen Elektrolysehalle Labor Ofenwannenentleeren Kathodenreparaturwerkstatt Gebrauchtanlagen Aluminiumlegierungen Lager und Transport Unloading/Loading equipment Entlade-/Beladeeinrichtungen Möller Materials Handling GmbH Internet: www.moeller-mh.com see Storage facilities for smelting 1.2 Open top and closed type baking furnaces Offene und geschlossene Ringöfen 1.3 Anode production Anodenherstellung TRIMET ALUMINIUM AG Niederlassung Düsseldorf Heinrichstr. 155 D-40239 Düsseldorf Tel.: +49 (0) 211 / 96180-0 Fax: +49 (0) 211 / 96180-60 Internet: www.trimet.de Outotec GmbH RIEDHAMMER GmbH D-90332 Nürnberg E-Mail: [email protected] Internet: www.riedhammer.de see Storage facilities for smelting 1.2 Auto firing systems Automatische Feuerungssysteme 1.4 Anode rodding Anodenanschlägerei Outotec GmbH see Storage facilities for smelting 1.2 1.2 Storage facilities for smelting Lagermöglichkeiten in der Hütte Möller Materials Handling GmbH Haderslebener Straße 7 D-25421 Pinneberg Telefon: 04101 788-0 Telefax: 04101 788-115 E-Mail: [email protected] Internet: www.moeller-mh.com Kontakt: Herr Dipl.-Ing. Timo Letz Outotec GmbH Phone: +49 (0) 2203 / 9921-0 www.outotec.com Conveying systems bulk materials Förderanlagen für Schüttgüter (Hüttenaluminiumherstellung) Möller Materials Handling GmbH Internet: www.moeller-mh.com see Storage facilities for smelting 1.2 112 RIEDHAMMER GmbH D-90332 Nürnberg E-Mail: [email protected] Internet: www.riedhammer.de Removal of bath residues from the surface of spent anodes Entfernen der Badreste von der Oberfläche der verbrauchten Anoden Exhaust gas treatment Tel. +47 22 12 70 00 Internet: www.environment.power.alstom.com GLAMA Maschinenbau GmbH Hornstraße 19 D-45964 Gladbeck Telefon 02043 / 9738-0 Telefax 02043 / 9738-50 Hydraulic presses for prebaked anodes / Hydraulische Pressen zur Transport of finished anode elements to the pot room Abgasbehandlung ALSTOM Norway AS Herstellung von Anoden LAEIS GmbH Am Scheerleck 7, L-6868 Wecker, Luxembourg Phone: +352 27612 0 Fax: +352 27612 109 E-Mail: [email protected] Internet: www.laeis-gmbh.com Contact: Dr. Alfred Kaiser Transport der fertigen Anodenelemente in Elektrolysehalle Hovestr. 10 . D-48431 Rheine Telefon + 49 (0) 59 71 58-0 Fax + 49 (0) 59 71 58-209 E-Mail [email protected] Internet www.windhoff.de ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS 1.5 Casthouse (foundry) Gießerei Degassing, filtration and grain refinement Entgasung, Filtern, Kornfeinung maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 HERTWICH ENGINEERING GmbH Maschinen und Industrieanlagen Weinbergerstraße 6, A-5280 Braunau am Inn Phone +437722/806-0 Fax +437722/806-122 E-Mail: [email protected] Internet: www.hertwich.com 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 Dross skimming of liquid metal Abkrätzen des Flüssigmetalls GLAMA Maschinenbau GmbH see Anode rodding 1.4 INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH Konstantinstraße 1a D 41238 Mönchengladbach Telefon +49 (02166) 987990 Telefax +49 (02166) 987996 E-Mail: [email protected] Internet: www.inotherm-gmbh.de Furnace charging with molten metal Ofenbeschickung mit Flüssigmetall GLAMA Maschinenbau GmbH see Anode rodding 1.4 Melting/holding/casting furnaces Schmelz-/Halte- und Gießöfen OTTO JUNKER GmbH see Extrusion 2 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Vollert Anlagenbau GmbH + Co. KG Stadtseestraße 12 D-74189 Weinsberg Tel. +49 (0) 7134 / 52-220 Fax +49 (0) 7134 / 52-222 E-Mail [email protected] Internet www.vollert.de Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4 Transport of liquid metal to the casthouse Transport von Flüssigmetall in Gießereien GLAMA Maschinenbau GmbH see Anode rodding 1.4 MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 SIGNODE® SYSTEM GMBH Packaging Equipment Non-Ferrous Specialist Team DSWE Magnusstr. 18, 46535 Dinslaken/Germany Telefon: +49 (0) 2064 / 69-210 Telefax: +49 (0) 2064 / 69-489 E-Mail: [email protected] Internet: www.signode.com Contact: Mr. Gerard Laks Stopinc AG Bösch 83 a CH-6331 Hünenberg Tel. +41/41-785 75 00 Fax +41/41-785 75 01 E-Mail: [email protected] Internet: www.stopinc.ch Bone ash / Knochenasche IMPERIAL-OEL-IMPORT Bergstraße 11, D 20095 Hamburg Tel. 040/338533-0, Fax: 040/338533-85 E-Mail: [email protected] Clay / Tonerde HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4 Treatment of casthouse off gases Behandlung der Gießereiabgase 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: [email protected] Internet: www.sistemteknik.com maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 1.6 Casting machines Gießmaschinen Metal treatment in the holding furnace OTTO JUNKER GmbH Metallbehandlung in Halteöfen maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Pig casting machines (sow casters) Transfer to the casting furnace maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Überführung in Gießofen see Extrusion 2 Masselgießmaschine (Sowcaster) GLAMA Maschinenbau GmbH see Anode rodding 1.4 TRIMET ALUMINIUM AG Niederlassung Düsseldorf Heinrichstr. 155 D-40239 Düsseldorf Tel.: +49 (0) 211 / 96180-0 Fax: +49 (0) 211 / 96180-60 Internet: www.trimet.de ALUMINIUM · 1-2/2008 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 see Equipment and accessories 2.11 Outotec GmbH see Storage facilities for smelting 1.2 113 LIEFERVERZEICHNIS Rolling and extrusion ingot and T-bars Sawing / Sägen Elektrolysehalle Formatgießerei (Walzbarren oder Pressbolzen oder T-Barren) HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 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: [email protected] Contact: Giovanni Magarotto Anode changing machine Anodenwechselmaschine GLAMA Maschinenbau GmbH see Anode rodding 1.4 Heat treatment of extrusion ingot (homogenisation) Vertical semi-continuous DC casting / Vertikales Stranggießen 1.9 Potroom Formatebehandlung (homogenisieren) maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Tapping vehicles Schöpffahrzeuge GLAMA Maschinenbau GmbH see Anode rodding 1.4 Crustbreakers / Krustenbrecher GLAMA Maschinenbau GmbH see Anode rodding 1.4 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Dry absorption units for electrolysis exhaust gases see Equipment and accessories 2.11 IUT Industriell Ugnsteknik AB see Extrusion 2 Horizontal continuous casting Horizontales Stranggießen maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Trockenabsorptionsanlage für Elektrolyseofenabgase ALSTOM Norway AS Tel. +47 22 12 70 00 Internet: www.environment.power.alstom.com Anode transport equipment Anoden Transporteinrichtungen GLAMA Maschinenbau GmbH see Anode rodding 1.4 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Billet Heating Furnaces 1.5 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 HF Messtechnik 1.8 Electrolysis cell (pot) Elektrolyseofen Scales / Waagen HF Measurementtechnology OPSIS AB Box 244, S-24402 Furulund, Schweden Tel. +46 (0) 46-72 25 00, Fax -72 25 01 E-Mail: [email protected] Internet: www.opsis.se Insulating bricks / Isoliersteine Promat GmbH – Techn. Wärmedämmung Scheifenkamp 16, D-40878 Ratingen Tel. +49 (0) 2102 / 493-0, Fax -493 115 [email protected], www.promat.de 1.15 Storage and transport HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Pot feeding systems maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Möller Materials Handling GmbH Internet: www.moeller-mh.com see Storage facilities for smelting 1.2 HUBTEX Maschinenbau GmbH & Co. KG Werner-von-Siemens-Str. 8 D-36041 Fulda Tel. +49 (0) 661 / 83 82-0 Fax +49 (0) 661 / 83 82-120 E-Mail: [email protected] Internet: www.hubtex.com 114 Beschickungseinrichtungen für Elektrolysezellen Lager und Transport ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Extrusion Strangpressen Extrusion billet preparation Extrusion equipment Section handling Heat treatment Measurement and control equipment Die preparation and care Second-hand extrusion plant Consultancy, expert opinion Surface finishing of sections Machining of sections Equipment and accessories Services 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 Pressbolzenbereitstellung Strangpresseinrichtungen Profilhandling Wärmebehandlung Mess- und Regeleinrichtungen Werkzeugbereitstellung und -pflege Gebrauchte Strangpressanlagen Beratung, Gutachten Oberflächenveredlung von Profilen Profilbearbeitung Ausrüstungen und Hilfsmittel Dienstleistungen Billet heating furnaces Öfen zur Bolzenerwärmung Hot shears / Warmscheren OTTO JUNKER GmbH see Extrusion 2 www.otto-junker-group.com 2.2 Extrusion equipment Jägerhausstr. 22 D – 52152 Simmerath Telefon: +49 2473 601 0 Telefax: +49 2473 601 600 E-Mail: [email protected] Kontakt: Herr Teichert / Flat Equipment Herr Dr. Menzler / Extruded Equipment Herr Donsbach / Foundry Equipment Kingsbury Road Curdworth UK - SUTTON COLDFIELD B76 9EE Telefon: +44 1675 470551 Telefax: +44 1675 470645 E-Mail: [email protected] Kontakt: Mr. Beard IUT Industriell Ugnsteknik AB Industrivägen 2 43892 Härryda, Sweden Telefon: +46 (0) 301 31510 Telefax: +46 (0) 301 30479 E-Mail: [email protected] Kontakt: Mr. Berge 2.1 Extrusion billet preparation Pressbolzenbereitstellung Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 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: [email protected] Internet: www.sistemteknik.com Billet heating units Anlagen zur Bolzenerwärmung OTTO JUNKER GmbH see Extrusion 2 Strangpresseinrichtungen Oilgear Towler GmbH Im Gotthelf 8 D 65795 Hattersheim Tel. +49 (0) 6145 3770 Fax +49 (0) 6145 30770 E-Mail: [email protected] Internet: www.oilgear.de SMS Meer GmbH Schloemann Extrusion Ohlerkirchweg 66 D-41069 Mönchengladbach Tel. +49 (0) 2161 / 3500 Fax +49 (0) 2161 / 3501667 E-Mail: [email protected] Internet: www.sms-meer.com Containers / Rezipienten KIND & CO., EDELSTAHLWERK, KG Bielsteiner Straße 128-130 D-51674 Wiehl Telefon: +49 (0) 2262 / 84 0 Telefax: +49 (0) 2262 / 84 175 E-Mail: [email protected] Internet: www.kind-co.de SIGNODE® SYSTEM GMBH Packaging Equipment Non-Ferrous Specialist Team DSWE Magnusstr. 18, 46535 Dinslaken/Germany Telefon: +49 (0) 2064 / 69-210 Telefax: +49 (0) 2064 / 69-489 E-Mail: [email protected] Internet: www.signode.com Contact: Mr. Gerard Laks ALUMINIUM · 1-2/2008 Billet transport and storage equipment Bolzen Transport- und Lagereinrichtungen OTTO JUNKER GmbH see Extrusion 2 SMS Meer GmbH see Extrusion equipment 2.2 115 LIEFERVERZEICHNIS Extrusion / Strangpressen Homogenising furnaces Homogenisieröfen Section cooling Profilkühlung OTTO JUNKER GmbH see Extrusion 2 OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB OTTO JUNKER GmbH see Extrusion 2 see Extrusion 2 Press control systems Pressensteuersysteme Oilgear Towler GmbH see Extrusion Equipment 2.2 SMS Meer GmbH see Extrusion equipment 2.2 Temperature measurement Temperaturmessung 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: [email protected] Internet: www.herrmannhieber.de SMS Meer GmbH see Extrusion equipment 2.2 Section saws Profilsägen OTTO JUNKER GmbH see Extrusion 2 Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 SMS Meer GmbH see Extrusion equipment 2.2 Puller equipment Ausziehvorrichtungen/Puller SMS Meer GmbH see Extrusion equipment 2.2 OTTO JUNKER GmbH see Extrusion 2 Profil-Lagereinrichtungen Heating and control equipment for intelligent billet containers Heizungs- und Kontrollausrüstung für intelligente Blockaufnehmer Section store equipment SMS Meer GmbH see Extrusion equipment 2.2 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: [email protected] Internet: www.herrmannhieber.de MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 2.3 Section handling Profilhandling SIGNODE® SYSTEM GMBH Packaging Equipment Non-Ferrous Specialist Team DSWE Magnusstr. 18, 46535 Dinslaken/Germany Telefon: +49 (0) 2064 / 69-210 Telefax: +49 (0) 2064 / 69-489 E-Mail: [email protected] Internet: www.signode.com Contact: Mr. Gerard Laks 116 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS Transport equipment for extruded sections KASTO Maschinenbau GmbH & Co. KG Industriestr. 14, D-77855 Achern Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300 [email protected] / www.kasto.de Hersteller von Band- und Kreissägemaschinen sowie Langgut- und Blechlagersystemen Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 OTTO JUNKER GmbH see Extrusion 2 Homogenisieröfen Transporteinrichtungen für Profilabschnitte 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: [email protected] Internet: www.herrmannhieber.de OTTO JUNKER GmbH see Extrusion 2 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 schwartz GmbH Section transport equipment Profiltransporteinrichtungen Homogenising furnaces Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de 2.4 Heat treatment Wärmebehandlung SMS Meer GmbH see Extrusion equipment 2.2 Extrusion Strangpressen see Billet Heating Furnaces 2.1 OTTO JUNKER GmbH see Extrusion 2 Stackers / Destackers Stapler / Entstapler OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 Heat treatment furnaces Wärmebehandlungsöfen Mess- und Regeleinrichtungen INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 SMS Meer GmbH see Extrusion equipment 2.2 2.5 Measurement and control equipment Extrusion plant control systems Presswerkssteuerungen OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 SMS Meer GmbH see Extrusion equipment 2.2 Stretching equipment Reckeinrichtungen see Billet Heating Furnaces 2.1 OTTO JUNKER GmbH see Extrusion 2 Custom designed heat processing equipment Kundenspezifische Wärmebehandlungsanlagen SMS Meer GmbH see Extrusion equipment 2.2 ALUMINIUM · 1-2/2008 Sistem Teknik Ltd. Sti. see Billet Heating Furnaces 2.1 Hardness measuring instuments, portable Härtemessgerät, tragbar Form+Test Seidner & Co. GmbH D-88491 Riedlingen Telefax 07371/9302-98 E-Mail: [email protected] 117 LIEFERVERZEICHNIS 2.6 Die preparation and care Werkzeugbereitstellung und -pflege Castool Tooling Solutions (North America) 21 State Crown Bvld Scarborough Ontario Canada MIV 4B1 Tel.: +1 416 297 1521 Fax: +1 416 297 1915 E-Mail: [email protected] Internet: www.castool.com Sales Contact: Danny Dann 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: [email protected] Die heating furnaces Werkzeuganwärmöfen IUT Industriell Ugnsteknik AB see Extrusion 2 MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 schwartz GmbH Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de Sistem Teknik Ltd. Sti. see Billet Heating Furnaces 2.1 2.11 Equipment and accessories Ageing furnace for extrusions Auslagerungsöfen für Strangpressprofile IUT Industriell Ugnsteknik AB see Extrusion 2 LOI Thermprocess GmbH Am Lichtbogen 29 D-45141 Essen Germany Telefon +49 (0) 201 / 18 91-3 10 Telefax +49 (0) 201 / 18 91-53 10 E-Mail: [email protected] Internet: www.loi.de Ausrüstungen und Hilfsmittel Inductiv heating equipment Induktiv beheizte Erwärmungseinrichtungen see Billet Heating Furnaces 2.1 Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de 2.12 Services Dienstleistungen Haarmann Holding GmbH see Die preparation and care 2.6 Extrusion dies Strangpresswerkzeuge Haarmann Holding GmbH Ludwigsallee 57 D-52052 Aachen Telefon: 02 41 / 9 18 - 500 Telefax: 02 41 / 9 18 - 5010 E-Mail: [email protected] Internet: www.haarmann-gruppe.de Hardening technology Härtetechnik Haarmann Holding GmbH see Die preparation and care 2.6 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 118 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 Rolling mill technology Walzwerktechnik Casting equipment Rolling bar machining Rolling bar furnaces Hot rolling equipment Strip casting units and accessories Cold rolling equipment Thin strip / foil rolling plant Auxiliary equipment Adjustment devices Process technology / Automation technology Coolant / lubricant preparation Air extraction systems Fire extinguishing units Storage and dispatch Second-hand rolling equipment Coil storage systems Strip Processing Lines 3.0 Rolling mill Technology Walzwerktechnik SMS Demag Aktiengesellschaft Eduard-Schloemann-Straße 4 D-40237 Düsseldorf Telefon: +49 (0) 211 881-0 Telefax: +49 (0) 211 881-49 02 Internet: www.sms-demag.com E-Mail: [email protected] Geschäftsbereiche: Warmflach- und Kaltwalzwerke Wiesenstraße 30 D-57271 Hilchenbach-Dahlbruch Telefon: +49 (0) 2733 29-0 Telefax: +49 (0) 2733 29-2852 Bandanlagen Walderstraße 51/53 D-40724 Hilden Telefon: +49 (0) 211 881-5100 Telefax: +49 (0) 211 881-5200 Elektrik + Automation Ivo-Beucker-Straße 43 D-40237 Düsseldorf Telefon: +49 (0) 211 881-5895 Telefax: +49 (0) 211 881-775895 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 Gießanlagen Walzbarrenbearbeitung Walzbarrenvorbereitung Warmwalzanlagen Bandgießanlagen und Zubehör Kaltwalzanlagen Feinband-/Folienwalzwerke Nebeneinrichtungen Adjustageeinrichtungen Prozesstechnik / Automatisierungstechnik Kühl-/Schmiermittel-Aufbereitung Abluftsysteme Feuerlöschanlagen Lagerung und Versand Gebrauchtanlagen Coil storage systems Bandprozesslinien maerz-gautschi Industrieofenanlagen GmbH Geschäftsbereich Aluminium Konstanzer Straße 37 Postfach 170 CH 8274 Tägerwilen Telefon +41/71/6666666 Telefax +41/71/6666688 E-Mail: [email protected] Kontakt: Stefan Blum, Tel. +41/71/6666621 Metal filters / Metallfilter maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Filling level indicators and controls SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Slab milling machines Barrenfräsmaschinen Füllstandsanzeiger und -regler maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Melt purification units Schmelzereinigungsanlagen maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 3.2 Rolling bar machining Walzbarrenbearbeitung 3.1 Casting equipment Bar scalping / Barrenfräsen Band saws / Bandsägen SMS Meer GmbH see Rolling bar machining 3.2 3.3 Rolling bar furnaces Walzbarrenvorbereitung Homogenising furnaces Homogenisieröfen Gießanlagen OTTO JUNKER GmbH see Extrusion 2 Melting and holding furnaces Schmelz- und Warmhalteöfen see Equipment and accessories 2.11 ALUMINIUM · 1-2/2008 SMS Meer GmbH Ohlerkirchweg 66 D-41069 Mönchengladbach Tel. +49 (0) 2161 / 3500 Fax +49 (0) 2161 / 3501667 E-Mail: [email protected] Internet: www.sms-meer.com HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 119 LIEFERVERZEICHNIS maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 3.4 Hot rolling equipment Spools / Haspel Warmwalzanlagen schwartz GmbH Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Hot rolling units / complete plants 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: [email protected] OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 SIEMAG GmbH Obere Industriestraße 8 D-57250 Netphen Tel.: +49 (0) 2738 / 21-0 Fax: +49 (0) 2738 / 21-1299 E-Mail: [email protected] Internet: www.siemag.com Coil transport systems Warmwalzanlagen/Komplettanlagen SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Bundtransportsysteme Toolings / Werkzeuge maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 schwartz GmbH Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4 see Extrusion equipment 2.2 see Heat treatment 2.4 Bar heating furnaces Barrenanwärmanlagen Drive systems / Antriebe Cores & shells for continuous casting lines SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Rolling mill modernisation OTTO JUNKER GmbH see Extrusion 2 Bandgießanlagen und Zubehör Cores & shells for continuous casting lines EBNER Industrieofenbau Ges.m.b.H. see Annealing furnaces 3.3 maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 3.5 Strip casting units and accessories Walzwerksmodernisierung Bruno Presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia Roller tracks Rollengänge maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Do you need more information? E-Mail: [email protected] 120 Revamps, equipments & spare parts for continuous casting lines Revamps, equipments & spare parts for continuous casting lines Bruno Presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS Twin-roll continuous casting lines (complete lines) Twin-roll continuous casting lines (complete lines) Bruno Presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia Coil annealing furnaces Bundglühöfen OTTO JUNKER GmbH see Extrusion 2 see Equipment and accessories 2.11 3.6 Cold rolling equipment Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de schwartz GmbH Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de schwartz GmbH Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de Vits Systems GmbH Winkelsweg 172 D-40764 Langenfeld Tel.: +49 (0) 2173 / 798-0 Fax: +49 (0) 2173 / 798-244 E-Mail: [email protected], Internet: www.vits.com www.vits.com Mainzer Landstrasse 16 D-60325 Frankfurt am Main Tel.: +49 69 97 16 81 48 Fax: +49 69 97 16 82 00 E-Mail: [email protected] Internet: www.pesmel.com maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 OTTO JUNKER GmbH IUT Industriell Ugnsteknik AB see Extrusion 2 maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Kaltwalzanlagen Heating furnaces / Anwärmöfen see Cold rolling equipment 3.6 Coil transport systems Bundtransportsysteme Process optimisation systems Prozessoptimierungssysteme maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 SIEMAG GmbH Obere Industriestraße 8 D-57250 Netphen Tel.: +49 (0) 2738 / 21-0 Fax: +49 (0) 2738 / 21-1299 E-Mail: [email protected] Internet: www.siemag.com SIGNODE® SYSTEM GMBH Packaging Equipment Non-Ferrous Specialist Team DSWE Magnusstr. 18, 46535 Dinslaken/Germany Telefon: +49 (0) 2064 / 69-210 Telefax: +49 (0) 2064 / 69-489 E-Mail: [email protected] Internet: www.signode.com Contact: Mr. Gerard Laks Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4 Process simulation Prozesssimulation maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Cold rolling units / complete plants Kaltwalzanlagen/Komplettanlagen SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Do you need more information? E-Mail: [email protected] ALUMINIUM · 1-2/2008 Drive systems / Antriebe Revamps, equipments & spare parts Revamps, equipments & spare parts SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Bruno Presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia 121 LIEFERVERZEICHNIS Roll exchange equipment Walzenwechseleinrichtungen 3.7 Thin strip / foil rolling plant Feinband-/Folienwalzwerke SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SIGNODE® SYSTEM GMBH Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4 Packaging Equipment Non-Ferrous Specialist Team DSWE Magnusstr. 18, 46535 Dinslaken/Germany Telefon: +49 (0) 2064 / 69-210 Telefax: +49 (0) 2064 / 69-489 E-Mail: [email protected] Internet: www.signode.com Contact: Mr. Gerard Laks schwartz GmbH Edisonstraße 5 D-52152 Simmerath Tel.: +49 (0) 2473 9488-0 Fax: +49 (0) 2473 9488-11 E-Mail: [email protected] Internet: www.schartz-wba.de Vits Systems GmbH Winkelsweg 172 D-40764 Langenfeld Tel.: +49 (0) 2173 / 798-0 Fax: +49 (0) 2173 / 798-244 E-Mail: [email protected], Internet: www.vits.com Thin strip / foil rolling mills / complete plant Feinband- / Folienwalzwerke / Komplettanlagen Coil annealing furnaces Bundglühöfen Rolling mill modernization OTTO JUNKER GmbH see Extrusion 2 Walzwerkmodernisierung Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 see Equipment and accessories 2.11 maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 Strip shears Bandscheren schwartz GmbH see Cold colling equipment 3.6 Revamps, equipments & spare parts Revamps, equipments & spare parts Bruno Presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia Rolling mill modernization Walzwerkmodernisierung www.vits.com see Thin strip / foil rolling plant 3.7 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Heating furnaces Anwärmöfen Trimming equipment Besäumeinrichtungen INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 Do you need more information? OTTO JUNKER GmbH see Extrusion 2 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 122 maerz-gautschi Industrieofenanlagen GmbH see Casting equipment 3.1 E-Mail: [email protected] ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS 3.9 Adjustment devices Adjustageeinrichtungen Process control technology Prozessleittechnik Strip flatness measurement and control equipment Bandplanheitsmess- und -regeleinrichtungen Sheet and plate stretchers Blech- und Plattenstrecker SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 SMS Meer GmbH see Rolling bar machining 3.2 Cable sheathing presses Kabelummantelungspressen Unitechnik Cieplik & Poppek AG D-51674 Wiehl, www.unitechnik.com Standards and Specifications Normen und Spezifikationen SMS Meer GmbH see Rolling bar machining 3.2 Cable undulating machines Kabelwellmaschinen ABB Automation Technologies AB Force Measurement S-72159 Västeras, Sweden Phone: +46 21 342000 Fax: +46 21 340005 E-Mail: [email protected] Internet: www.abb.com/pressductor ExcSol GmbH Im Burggarten 23, D-53507 Dernau Tel.: +49 (0) 2643/90 02 56, [email protected] Walzwerke / Beratung / Programmierung *Normen / Spez. in Datenbanken *Produktkatalog / Prüfungen / Zeugnisse *Prozess-/Qualitätsmanagement Strip thickness measurement and control equipment Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Banddickenmess- und -regeleinrichtungen 3.11 Coolant / lubricant preparation SMS Meer GmbH see Rolling bar machining 3.2 ABB Automation Technologies AB Force Measurement S-72159 Västeras, Sweden Phone: +46 21 342000 Fax: +46 21 340005 E-Mail: [email protected] Internet: www.abb.com/pressductor Kühl-/SchmiermittelAufbereitung Rolling oil recovery and treatment units Walzöl-Wiederaufbereitungsanlagen 3.10 Process technology / Automation technology Prozesstechnik / Automatisierungstechnik 4Production AG Produktionsoptimierende Lösungen Adenauerstraße 20, D-52146 Würselen Tel.: +49 (0) 2405 / 4135-0 [email protected], www.4production.de Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Filter for rolling oils and emulsions Filter für Walzöle und Emulsionen SIEMAG GmbH Obere Industriestraße 8 D-57250 Netphen Tel.: +49 (0) 2738 / 21-0 Fax: +49 (0) 2738 / 21-1299 E-Mail: [email protected] Internet: www.siemag.com ALUMINIUM · 1-2/2008 SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de 123 LIEFERVERZEICHNIS Rolling oil rectification units Filtering plants and systems Walzölrektifikationsanlagen Filteranlagen und Systeme 3.17 Strip Processing Lines Bandprozesslinien Strip Processing Lines Bandprozesslinen Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Dantherm Filtration GmbH Industriestr. 9, D-77948 Friesenheim Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 E-Mail: [email protected] Internet: www.danthermfiltration.com 3.14 Storage and dispatch Lagerung und Versand SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 3.12 Air extraction systems Abluft-Systeme Exhaust air purification systems (active) Mainzer Landstrasse 16 D-60325 Frankfurt am Main Tel.: +49 69 97 16 81 48 Fax: +49 69 97 16 82 00 E-Mail: [email protected] Internet: www.pesmel.com SIEMAG GmbH Obere Industriestraße 8 D-57250 Netphen Tel.: +49 (0) 2738 / 21-0 Fax: +49 (0) 2738 / 21-1299 E-Mail: [email protected] Internet: www.siemag.com Abluft-Reinigungssysteme (aktiv) BWG Bergwerk- und WalzwerkMaschinenbau GmbH Mercatorstraße 74 – 78 D-47051 Duisburg Tel.: +49 (0) 203-9929-0 Fax: +49 (0) 203-9929-400 E-Mail: [email protected] Internet: www.bwg-online.com Colour Coating Lines Bandlackierlinien www.bwg-online.com see Strip Processing Lines 3.17 Strip Annealing Lines Bandglühlinien www.bwg-online.com see Strip Processing Lines 3.17 3.16 Coil storage systems Bundlagersysteme Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Stretch Levelling Lines Streckrichtanlagen SIEMAG GmbH Obere Industriestraße 8 D-57250 Netphen Tel.: +49 (0) 2738 / 21-0 Fax: +49 (0) 2738 / 21-1299 E-Mail: [email protected] Internet: www.siemag.com www.bwg-online.com see Strip Processing Lines 3.17 Lithographic Sheet Lines Lithografielinien SMS Demag Aktiengesellschaft see Rolling mill Technology 3.0 Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 www.bwg-online.com see Strip Processing Lines 3.17 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] 124 ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 Foundry Gießerei Work protection and ergonomics Heat-resistant technology Conveyor and storage technology Mould and core production Mould accessories and accessory materials Foundry equipment Casting machines and equipment Handling technology Construction and design Measurement technology and materials testing Metallic charge materials Finshing of raw castings Melt operations Melt preparation Melt treatment devices Control and regulation technology Environment protection and disposal Dross recovery 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 [email protected], www.promat.de 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 Arbeitsschutz und Ergonomie Feuerfesttechnik Förder- und Lagertechnik Form- und Kernherstellung Formzubehör, Hilfsmittel Gießereianlagen Gießmaschinen und Gießeinrichtungen Handhabungstechnik Konstruktion und Design Messtechnik und Materialprüfung Metallische Einsatzstoffe Rohgussnachbehandlung Schmelzbetrieb Schmelzvorbereitung Schmelzebehandlungseinrichtungen Steuerungs- und Regelungstechnik Umweltschutz und Entsorgung Schlackenrückgewinnung Cast parts 4.6 Foundry equipment Gießereianlagen Casting machines Gießmaschinen see Equipment and accessories 2.11 see Billet Heating Furnaces 2.1 4.7 Casting machines and equipment Gießereimaschinen und Gießeinrichtungen OTTO JUNKER GmbH 4.3 Conveyor and storage technology Förder- und Lagertechnik see Extrusion 2 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Molten Metall Level Control Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 Solution annealing furnaces/plant Lösungsglühöfen/anlagen 4.5 Mold accessories and accessory materials Formzubehör, Hilfmittel ERNST REINHARDT GMBH Postfach 1880, D-78008 VS-Villingen Tel. 07721/8441-0, Fax 8441-44 E-Mail: [email protected] Internet: www.Ernst-Reinhardt.com Fluxes Flussmittel Solvay Fluor GmbH Hans-Böckler-Allee 20 D-30173 Hannover Telefon +49 (0) 511 / 857-0 Telefax +49 (0) 511 / 857-2146 Internet: www.solvay-fluor.de ALUMINIUM · 1-2/2008 Heat treatment furnaces Wärmebehandlungsöfen see Foundry equipment 4.6 Ostra Hamnen 7 SE-430 91 Hono / Schweden Tel.: +46 31 764 5520 Fax: +46 31 764 5529 E-mail: [email protected] Internet: www.precimeter.se Sales Contact: Rolf Backberg Mould parting agents Kokillentrennmittel Schröder KG Schmierstofftechnik Postfach 1170 D-57251 Freudenberg Tel. 02734/7071 Fax 02734/20784 www.schroeder-schmierstoffe.de 125 LIEFERVERZEICHNIS Melting furnaces 4.8 Handling technology Schmelzöfen Handhabungstechnik Vollert Anlagenbau GmbH + Co. KG see Transfer to the casting furnace 1.5 4.9 Construction and Design Konstruktion und Design THERMCON OVENS BV see Extrusion 2 4.11 Metallic charge materials ALERIS Recycling (German Works) GmbH Aluminiumstraße 3 D-41515 Grevenbroich Telefon +49 (0) 2181/16 45 0 Telefax +49 (0) 2181/16 45 100 E-Mail: [email protected] Internet: www.aleris-recycling.com Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-43 Fax: +49 (0) 211 / 50 13 97 E-Mail: [email protected] Internet: www.bloomeng.com Sales Contact: Klaus Rixen Pre alloys / Vorlegierungen METALLHANDELSGESELLSCHAFT SCHOOF & HASLACHER MBH & CO. KG Postfach 600714, D 81207 München Telefon 089/829133-0 Telefax 089/8201154 E-Mail: [email protected] Internet: www.metallhandelsgesellschaft.de Recycling / Recycling HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Equipment and accessories 2.11 Metallische Einsatzstoffe Scholz AG Am Bahnhof D-73457 Essingen Tel. +49 (0) 7365-84-0 Fax +49 (0) 7365-1481 E-Mail: [email protected] Internet: www.scholz-ag.de Aluminium alloys Aluminiumlegierungen TRIMET ALUMINIUM AG Niederlassung Gelsenkirchen Am Stadthafen 51-65 D-45681 Gelsenkirchen Tel.: +49 (0) 209 / 94089-0 Fax: +49 (0) 209 / 94089-60 Internet: www.trimet.de maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 TRIMET ALUMINIUM AG Niederlassung Harzgerode Aluminiumallee 1 06493 Harzgerode Tel.: 039484 / 50-0 Fax: 039484 / 50-100 Internet: www.trimet.de Holding furnaces Warmhalteöfen 4.13 Melt operations Schmelzbetrieb METALLHÜTTENWERKE BRUCH GMBH Postfach 10 06 29 D-44006 Dortmund Telefon +49 (0) 231 / 8 59 81-121 Telefax +49 (0) 231 / 8 59 81-124 E-Mail: [email protected] Internet: www.bruch.de MARX GmbH & Co. KG Lilienthalstr. 6-18 D-58638 Iserhohn Tel.: +49 (0) 2371 / 2105-0, Fax: -11 E-Mail: [email protected] Internet: www.marx-gmbh.de OTTO JUNKER GmbH see Extrusion 2 Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-43 Fax: +49 (0) 211 / 50 13 97 E-Mail: [email protected] Internet: www.bloomeng.com Sales Contact: Klaus Rixen Heat treatment furnaces Wärmebehandlungsanlagen METALLHANDELSGESELLSCHAFT SCHOOF & HASLACHER MBH & CO. KG Postfach 600714, D 81207 München Telefon 089/829133-0 Telefax 089/8201154 E-Mail: [email protected] Internet: www.metallhandelsgesellschaft.de 126 see Equipment and accessories 2.11 see Billet Heating Furnaces 2.1 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 ALUMINIUM · 1-2/2008 LIEFERVERZEICHNIS Heat treatment furnaces Wärmebehandlungsanlagen 4.16 Control and regulation technology Flue gas cleaning Rauchgasreinigung Steuerungs- und Regelungstechnik HCL measurements HCL Messungen HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 OPSIS AB Box 244, S-24402 Furulund, Schweden Tel. +46 (0) 46-72 25 00, Fax -72 25 01 E-Mail: [email protected] Internet: www.opsis.se Dantherm Filtration GmbH Industriestr. 9, D-77948 Friesenheim Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 E-Mail: [email protected] Internet: www.danthermfiltration.com 4.18 Dross recovery Schlackenrückgewinnung see Equipment and accessories 2.11 OTTO JUNKER UK see Extrusion 2 maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 4.17 Environment protection and disposal 4.19 Cast parts / Gussteile Umweltschutz und Entsorgung 4.14 Melt preparation Schmelzvorbereitung Dust removal / Entstaubung OTTO JUNKER GmbH see Extrusion 2 Degassing, filtration Entgasung, Filtration NEOTECHNIK GmbH Entstaubungsanlagen Postfach 110261, D-33662 Bielefeld Tel. 05205/7503-0, Fax 05205/7503-77 [email protected], www.neotechnik.com TRIMET ALUMINIUM AG Niederlassung Harzgerode Aluminiumallee 1 06493 Harzgerode Tel.: 039484 / 50-0 Fax: 039484 / 50-100 Internet: www.trimet.de maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 Drache Umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: http://www.drache-gmbh.de Do you need more information? E-Mail: [email protected] Melt treatment agents Schmelzebehandlungsmittel maerz-gautschi Industrieofenanlagen GmbH see Casting Equipment 3.1 4.15 Melt treatment devices Schmelzbehandlungseinrichtungen OTTO JUNKER GmbH see Extrusion 2 Metaullics Systems Europe B.V. P.O.Box 748 NL-2920 CA Krimpen a/d Yssel Tel. +31-180/590890 Fax +31-180/551040 E-Mail: [email protected] Internet: www.metaullics.com ALUMINIUM · 1-2/2008 5 Materials and Recycling Werkstoffe und Recycling Alu-web.de der ALUMINIUMBranchentreff. Haben Sie schon Ihren Basiseintrag bestellt? Nein, dann sofort anrufen: 0511/73 04-142 Stefan Schwichtenberg Granulated aluminium Aluminiumgranulate ECKA Granulate Austria GmbH Bürmooser Landesstraße 19 A-5113 St. Georgen/Salzburg Telefon +43 6272 2919-12 Telefax +43 6272 8439 Kontakt: Ditmar Klein E-Mail: [email protected] 127 LIEFERVERZEICHNIS 6 Machining and Application Bearbeitung und Anwendung Machining of aluminium Joining / Fügen Aluminiumbearbeitung KGaA Haarmann Holding GmbH Henkel siehe Prozesse für die Oberflächentechnik 6.1 see Die preparation and care 2.6 6.1 Surface treatment processes Prozesse für die Oberflächenbehandlung Pretreatment before coating Vorbehandlung vor der Beschichtung siehe Prozesse für die Oberflächentechnik 6.1 Thermische Beschichtung Adhesive bonding / Verkleben 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: [email protected] Internet: www.lasco.com Henkel KGaA Thermal coating Henkel KGaA D-40191 Düsseldorf Tel. +49 (0) 211 / 797-30 00 Fax +49 (0) 211 / 798-36 36 Internet: www.henkel-technologies.com 6.3 Equipment for forging and impact extrusion Berolina Metallspritztechnik Wesnigk GmbH Pappelhain 30 D-15378 Hennickendorf Tel.: +49 (0) 33434 / 46060 Fax: +49 (0) 33434 / 46701 E-Mail: [email protected] Internet: www.metallspritztechnik.de Henkel KGaA siehe Prozesse für die Oberflächentechnik 6.1 8 Literature Literatur Technikcal literature Fachliteratur Taschenbuch des Metallhandels Fundamentals of Extrusion Technology Giesel Verlag GmbH Verlag für Fachmedien Ein Unternehmen der Klett-Gruppe Rehkamp 3 · 30916 Isernhagen Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157 Internet: www.alu-bookshop.de. 6.2 Semi products Anodising / Anodisation Henkel KGaA siehe Prozesse für die Oberflächentechnik 6.1 Cleaning / Reinigung Henkel KGaA siehe Prozesse für die Oberflächentechnik 6.1 Halbzeuge Wires / Drähte Fachzeitschriften 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: [email protected] Internet: www.elisental.de Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] 128 Technical journals Giesel Verlag GmbH Ein Unternehmen der Klett-Gruppe Rehkamp 3 · 30916 Isernhagen Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157 ALUMINIUM · 1-2/2008 IMPRESSUM / IMPRINT International ALUMINIUM Journal 84. Jahrgang 1.1.2008 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: [email protected] 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, Unternehmen der Klett-Gruppe, Postfach 120158, 30907 Isernhagen; Rehkamp 3, 30916 Isernhagen, Tel: 0511/7304-0, Fax: 0511/7304-157. E-mail: [email protected] Internet: www.alu-web.de. 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Wissing Oestbanegade 11 DK-2100 Kopenhagen Tel: +45(0)35 385255 Fax: +45 (0)35 385220 E-Mail: [email protected] France DEF & Communication Axelle Chrismann 48 boulevard Jean Jaurès F-92110 Clichy Tel: +33 (0)1 47 30 71 80, Fax: +33 (0)1 47 30 01 89 E-Mail: [email protected] Der ALUMINIUM-Branchentreff des Giesel Verlags: www.alu-web.de 129 VORSCHAU / PREVIEW IM NÄCHSTEN HEFT IN THE NEXT ISSUE Special: Aluminium-Recycling und Schmelztechnologien Special: Aluminium recycling and melting technologies Branchen- und Marktentwicklung, internationale Herausforderungen, Technologietrends. Beiträge unter anderem über: • Höhere Produktivität von Schmelzöfen durch schienengebundene Chargiermaschinen • Kipptrommelofen ersetzt herkömmlichen Flammofen zum Schmelzen • Globale Perspektiven des Aluminiumrecyclings Industry and market development, global challenges, trends in technology. Subjects covered include: • Increased melt furnace productivity by rail-bound charging machines • Tilt rotary replacing traditional reverberatory melting • Global perspectives of aluminium recycling Markt und Technik Markets and technology • Die „Renaissance“ des Niederdruckgießens – CST-Gruppe mit ganzheitlichem GießtechnologieKonzept • ‘Renaissance’ of low pressure casting – CST group’s integrated casting solutions concept Research Powder metallurgical development of aluminium foam production by introduction of foamable bulk material Pulvermetallurgische Weiterentwicklung der Aluminiumschaumherstellung durch Einführung schäumbaren Schüttguts Research Erscheinungstermin: 3. März 2008 Anzeigenschluss: 15. Februar 2008 Redaktionsschluss: 14. 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Name / name Firma / company Anschrift / address Umsatzsteuer-Ident.-Nr. / VAT Reg.-No. Datum / date Unterschrift/Signature Fax: +49 (0) 511 73 04 157 130 ALUMINIUM · 1-2/2008 4 Media-Informationen 2008 Termin- und Themenplan Giesel Verlag GmbH, Rehkamp 3, D-30916 Isernhagen, Telefon +49(0)511 / 7304-0, Telefax +49(0)511 / 7304-157 Ausgabe Termine 1/2 ET: 05. 02. AS: 21. 01. RS: 18. 01. 3 ET: 03. 03. AS: 15. 02. RS: 14. 02. 4 ET: 04. 04. AS: 21. 03. RS: 20. 03. 5 ET: 02. 05. AS: 18. 04. RS: 17. 04. 6 ET: 02. 06. AS: 16. 05. RS: 15. 05. 7/8 ET: 01. 08. AS: 17. 07. RS: 15. 07. 9 ET: 01. 09. AS: 15. 08. RS: 14. 08. 10 ET: 02. 10. AS: 17. 09. RS: 16. 09. 11 ET: 03. 11. AS: 17. 10. RS: 16. 10. 12 ET: 01. 12. AS: 14. 11. RS: 13. 11. Fachteil / Märkte / Anwendungen Themenschwerpunkt / Special Messen / Veranstaltungen Die internationale Hüttenindustrie: Verfahren, Anlagen, neue Projekte, Ausrüstungen und Bezugsquellen Gezielte Verbreitung in internationalen Hütten und Umschmelzwerken Fachberichte: Casthouse Solutions ALUMINIUM India 2008 22. - 24. 2. 2008 Mumbai, Indien TMS Annual Meeting & Exhibition 9. - 13. 3. 2008 New Orleans, USA Recycling und Schmelztechnologien: Branchen- und Marktentwicklung, internationale Herausforderungen, Technologietrends, Ausrüstungen und Bezugsquellen Marktbericht: China / Asien Euroguss 11. - 13. 3. 2008 Nürnberg Aluminiumbearbeitung: Neue Entwicklungen und Trends, Verfahren, Werkzeuge und Maschinen Märkte: Aluminium in der Verpackung Hannover Messe 21. - 25. 4. 2008 Metef 9. - 12. 4. 2008 Brescia, Italien Die internationale Strangpressindustrie: Maschinen und Anlagen, Technologien, Messund Regeltechnik, Projekte, F&E Gezielte Verbreitung in der internationalen Strangpressbranche Profilbearbeitung: Spanen, Umformen, Fügen, etc. ALUMINIUM CHINA 2008 28. - 30. 5. 2008 Guangzhou, China Aluminiumguss: Neue Technologien, Anlagen, Gießöfen, Formenbau, Mess- und Regelungstechnik, Ausrüstungen und Bezugsquellen Marktbericht: Produkte und Anwendungen aus Aluminiumguss O&S 3. - 5. 6. 2008 Stuttgart euroLITE 24. - 26. 6. 2008, Salzburg Vorschauf auf ALUMINIUM 2008: Aussteller stellen sich vor, detaillierte Vorberichte Wärmebehandlung von Aluminium: Anlagen, Verfahren, Projekte, Ausrüstungen Vorschauf auf ALUMINIUM 2008: Vorberichte, Firmenporträts, Aussteller-Interviews und weitere Informationen im Vorfeld der Messe Leichtbautrends: Anwendungen, Werkstoffe, Verfahren, Strategie ALUMINIUM 2008 23. - 25. 9. 2008, Essen 11. Int. Conf. on Aluminium Alloy 22. - 26. 9. 2008, Aachen Die internationale Walzwerkindustrie: Walzen, Bandguss, Bandbehandlung – neue Technologien, Maschinen, Ausrüstungen und Bezugsquellen Gezielte Verbreitung in der intern. Walzwerkbranche Marktberichte: Die deutsche und europäische Walzbranche Aluminiumblech: Verarbeitung und Anwendung Interpart 7. - 9. 10. 2008, Karlsruhe SURFACTS 7. - 9. 10. 2008, Karlsruhe EuroBlech 2008 21. - 25. 10. 2008, Hannover parts2clean 28. - 30. 10. 2008, Stuttgart Oberflächentechnik: Verfahren, Anlagen, Anwendungen, Qualitätsmanagement, Liefermöglichkeiten Märkte: Aluminium im Verkehr Fügetechniken: Technologien, Anlagen, Verfahren, Ausrüstungen, Anwendungen Schweißen von Aluminium: Aktuelle Entwicklungen Märkte: Aluminium im Bauwesen Die Themenschwerpunkte bestimmen nicht den Gesamtinhalt. Aktuelle Beiträge ergänzen die jeweilige Berichterstattung. Änderungen vorbehalten. ET = Erscheinungstermin Bau 2009 12. - 17. 1. 2009 München AS = Anzeigenschluss RS = Redaktionsschluss 5 Simply closer to your products. Your technology partner in the aluminum industry. How do we meet the growing demands of our customers in the aluminum industry worldwide? By supplying all-inclusive mechatronic solutions. Whatever you want to manufacture from this material, or what product quality you aim to achieve – at SMS Demag we know what it takes. That’s because we listen! And because we draw on our holistic process know- how and experience. Our plants – whether new facilities, conversions or revamps – always ensure that our solutions encompass the latest developments in aluminum production and processing. Always closer to you – SMS Demag. MEETING your EXPECTATIONS SMS DEMAG AG Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany Phone: +49 (0) 211 881-0 Fax: +49 (0) 211 881-4902 E-mail: [email protected] Internet: www.sms-demag.com