Special 2010:
The aluminium
recycling industry
Dubal celebrates major
production milestone
A busy time in the
Danieli Fröhling workshop
Interview mit Thomas
Reuther über das Recyclinggeschäft der Trimet
Trimet
Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-web.de – PVST H 13410 – Dt. Post AG – Entgelt bezahlt
OFFICIAL INTERNATIONAL
MEDIA PARTNER
Volume 86 · March 2010
International Journal for Industry, Research and Application
3
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eDitoRial
Volker Karow
Chefredakteur
Editor in Chief
Die Recyclingbranche
vor gravierenden
Herausforderungen
Recycling industry
faced by serious
challenges
ALUMINIUM · 3/2010
Die Aluminiumrecyclingbranche in
Europa hat ein sehr schwieriges Jahr
hinter sich. Die Produktion von Gusslegierungen brach im vergangenen
Jahr drastisch ein, weil sie zu rund 75
bis 80 Prozent vom Wohl und Wehe
der Automobilindustrie abhängt. Viele
Betriebe mussten Insolvenz anmelden, weil sie mit einer dünnen Eigenkapitaldecke und geringen Reserven
ausgestattet sind, die das Überdauern
einer Durststrecke schwierig machen.
Die Banken sind zudem sehr zurückhaltend bei der Finanzierung von Umlaufvermögen; Kredite werden, wenn
überhaupt, nur zu harten Konditionen
vergeben.
Inzwischen weisen die monatlichen Produktionszahlen für Sekundäraluminium wieder positive Vorzeichen zum Vorjahreszeitraum auf,
aber die grundsätzlichen Probleme
der mittelständisch strukturierten Industrie sind damit längst nicht gelöst.
Die Branche braucht Konsolidierung.
Die Anforderungen seitens der Autohersteller an die Entwicklung von
Sekundärlegierungen werden steigen. Das verlangt entsprechendes
F&E-Knowhow bei den Umschmelzern, das in kleinen Betrieben nicht
vorhanden ist. Hinzu kommt, dass
Knetlegierungen im Automobil wachsende Bedeutung erlangen. Bei den
langen Produktzyklen eines PkwModells sind die Automobilhersteller vermehrt an Partnerschaften mit
Zulieferern auf der Gießerei- und
Umschmelzseite interessiert, von
denen man erwarten kann, dass sie
auch in zehn Jahren noch am Markt
sein werden. Bei alledem ist nicht zu
vergessen, dass der westeuropäische
Automobilmarkt gesättigt ist und das
dynamische Nachfragewachstum in
den Schwellenländern stattfindet.
Das wird langfristig zu Produktionsverschiebungen führen, die die Gießerei- und Recyclingbranche massiv
berühren werden.
Diesen marktorientierten Herausforderungen stehen die umweltpolitischen zu Seite. Noch immer ist
offen, inwieweit Brüssel Ausnahmeregelungen beim Emissionshandel
ab 2013 für die Recyclingbranche
gewährt. Die wären nur logisch und
konsequent in einem Europa, das
sich im Umwelt- und Klimaschutz an
die Spitze der Welt setzen will. Aber
wann geht es in der Politik schon logisch und konsequent zu?
The aluminium recycling sector in
Europe has come through an extremely difficult year. In 2009 the production of casting alloys fell drastically,
since it depends to an extent of 75 to
80 percent on the wellbeing and woes
of the automobile industry. Many
companies had to declare insolvency
because their slim equity position
and low reserves made it impossible
to survive in so hard an environment.
Besides, the banks were very reluctant to finance working capital; when
credit was available at all, it was only
granted subject to stringent conditions.
Since then monthly production figures have improved again compared
with those of last year, but the fundamental problems of the recycling industry with its medium-sized corporate structure are still far from solved.
Consolidation is needed in the sector.
Requirements on the part of automobile manufacturers relating to the
development of secondary alloys are
becoming stricter, and this demands
corresponding levels of research and
development know-how from remelters which are not in place in small
companies. Another factor is that in
automotive engineering wrought alloys are gaining importance. Over the
long product cycles of a passenger
car model car makers are increasingly interested in partnerships with
suppliers on the foundry and remelting side who can be expected still to
be in business in ten years. On top of
all that, it must be remembered that
the automobile market in Western
Europe is virtually saturated; nowadays, dynamic demand growth takes
place in the developing countries. In
the long term that will result in production relocations which will have
a massive effect on the foundry and
recycling industry.
These market-orientated challenges are compounded by environment
policy issues. It is still an open question how far Brussels will go toward
providing support for the recycling
sector with exemption regulations on
emissions trading from 2013 onwards.
That would be no more than logical
and consistent in a Europe which
wants to lead the world in the field of
environment and climate protection.
But how often do logic and consistency find their way into politics?
i N H a lt
eDitoRial
Die Recyclingbranche vor gravieren den Herausforderungen ............ a Kt U e l l e S
Personen, Unternehmen, Märkte ..................................... ....... 6
WiRtSCHaFt
14
Englischsprachige Artikel: s. nebenstehendes Verzeichnis
Aluminiumpreise ......................................................... ..... 10
Produktionsdaten der deutschen Aluminiumindustrie .................. 12
Druckgussindustrie sieht Chancen für zweistelliges Wachstum 2010 20
SPeCial: alUMiNiUMReCYCliNGiNDUStRie
Englischsprachige Artikel: s. nebenstehendes Verzeichnis
VAR-Vorsitzender Oetinger zu Aluminiumschrottexporten nach China:
„Klimatische Entwicklungshilfe gefährdet Versorgung in Europa“ .... 24
28
Gutachten im Auftrag der Scholz Aluminium GmbH:
CO 2 -Emission der Sekundärroute beträgt nur vier
Prozent der Primärroute ....................................................... 25
Interview mit Thomas Reuther, Vorstandsmitglied der Trimet: „Wir
bieten die klassischen Stärken des Mittelstandes: kurze Entscheidungswege, gesunde Finanzstruktur, marktnahes Management“ ...... t e CH N o lo G i e
Englischsprachige Artikel: s. nebenstehendes Verzeichnis
Hochbetrieb in der Werkstatt von Danieli Fröhling:
Das Krisenjahr 2009 gut gemeistert ....................................... 4
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 ................... 49
R e S e a R C H ........................................................... ..... 55
Englischsprachige Artikel: s. nebenstehendes Verzeichnis
D o K U M e N tat i o N
Bücher .......................................................................... 60
8
Patente ......................................................................... 60
Impressum ..................................................................... 81
Vorschau........................................................................ 82
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 ....................... ..... 6
ALUMINIUM · 3/2010
CONTENTS
EDITORIAL
Recycling industry faced by serious challenges ............................ 3
NEWS IN BRIEF
People, companies, markets . . . . . . . . . . . . . ..................................... 7
ECONOMICS
43
Bauxite and alumina activities in 2009, Part I ........................... 14
Dubal celebrates major production milestone ........................... 17
Emal delivers to first local customer . . . .................................... 18
Die casting industry expects double-digit growth in 2010 ............. 20
SPECIAL: ALUMINIUM RECYCLING INDUSTRY
Scrap exports to China threaten supplies in Europe in the long term 27
Secondary aluminium smelting activities in 2009 ....................... 28
T. T. Tomorrow Technology celebrates its 10 th anniversary ............. 38
Remelting and refining modes in advanced recycling of
wrought aluminium alloys, Part I . . . . . . . ................................... 39
47
T E CH N O LO GY
A busy time in the Danieli Fröhling workshop:
The crisis year 2009 overcome well . . . .................................... 43
Technology breakthrough in the production of aluminium ingots .... 47
C O M PA N Y N E W S W O R L D W I D E
Aluminium smelting industry . . . . . . . . . . . .................................... 49
Bauxite and alumina activities . . . . . . . . . . .................................... 50
Recycling and secondary smelting . . . . . .................................... 51
Aluminium semis . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 52
Inserenten
dieser Ausgabe
On the move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................... 54
List of advertisers
Suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 54
ABB Automation Technologies, Sweden
Buss AG, Schweiz
Coiltec Maschinenvertriebs GmbH
Danieli Fröhling Josef Fröhling
GmbH & Co. KG
Drache Umwelttechnik GmbH
F. W. Brökelmann Aluminiumwerk
GmbH & Co. KG
Hertwich Engineering GmbH, Österreich
LOI Thermprocess GmbH
Inotherm Industrieofen- und
Wärmetechnik GmbH
Meed Middle East Business Intelligence
Reed Exhibitions Deutschland GmbH
Shanghai Jieru, PRC
SMS Siemag AG
Zhengzhou Zhongshi Cell
Technology Co., Ltd, PRC
RESEARCH
Innovative joining methods for lightweight designs, Part II .......... 55
D O C U M E N TAT I O N
Imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 81
Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 82
S O U R C E O F S U P P LY L I S T I N G ............................... 63
ALUMINIUM · 3/2010
29
31
53
45
15
37
2
23
16
19
35
13
84
11
5
Aktuelles
Achenbach liefert Folienwalzlinie nach China
0 Jahre: Axel e. Barten
Vertragsunterzeichnung für eine weitere Gesamtanlage zur Folienproduktion: In den ersten Tagen des neuen
Jahres 2010 hat das chinesische Un-
„Optiroll“-Automatisierungspaket,
modernste Antriebstechnik und „Superstack II“-Filtrationsanlagen zur
Walzölfeinstfiltration. Die Produkti-
Achenbach
Seit 1981 ist Dipl.-Ing. ETH Axel E.
Barten Geschäftsführender Gesellschafter der Achenbach Buschhütten
GmbH. Barten, der am 2. Dezember
2009 seinen 60. Geburtstag feierte,
sieht sich als ein Glied in der langen
Kette von Familieneigentümern des
Unternehmens. Auch Barten hat
Achenbach bis heute erfolgreich geführt und weiterentwickelt. Dies zeigt
sich u. a. in der Verdreifachung des
Firmenumsatzes, in der Erschließung
neuer Absatzmärkte weltweit und im
strukturellen Umbau des Unternehmens zu einem Hightech-Anlagenbauer: für NE-Metalle wie Aluminium,
Kupfer, Zink und deren Legierungen,
für die dazugehörenden Umweltschutzanlagen und für Schneid- und
Wickelmaschinen für Feinband und
Folie aus Aluminium.
Bis heute ist Barten sehr stark an
moderner Walzwerktechnik interessiert. Er ist davon überzeugt, dass herausragende Technik der Schlüsselfak-
ternehmen Luoyang Wanji Aluminium Processing den Auftrag zur Lieferung, Montage und Inbetriebnahme
einer dreigerüstigen Folienwalzlinie
für 2.000 mm breite Aluminiumbänder an Achenbach Buschhütten erteilt. Der Lieferumfang umfasst neben
den drei Walzgerüsten das komplette
onsaufnahme ist für Ende 2011 geplant. Die Unterzeichner von links
nach rechts: Thomas Kaup, Managing
Director, Ferrostaal AG; Guo Feng,
Executive General Manager, Luoyang
Wanji Aluminium Processing; Rolf
Wilbers, Executive Director Sales,
Achenbach Buschhütten GmbH.
Achenbach
Zenergy Power und Bültmann mit
BDI-Innovationspreis ausgezeichnet
tor im Geschäft mit Walzwerkanlagen
ist. Barten engagiert sich in hohem
Maße ehrenamtlich sowohl regional
als auch fachgebunden in den entsprechenden Maschinenbauverbänden. Zudem gehörte er 1992 zu den
Gründern des Fachverbandes „Hüttenund Walzwerkeinrichtungen“, ist dort
seitdem im Vorstand, dessen Vorsitz
er von 2001 bis 2009 innehatte.
Die Redaktion ALUMINIUM gratuliert nachträglich zum Geburtstag.
Der Bundesverband der deutschen Industrie (BDI), hat den weltweit ersten
Industriemaschinentyp in Supraleitertechnik mit dem Innovationspreis
Klima und Umwelt ausgezeichnet. Es
handelt sich bei dem Aggregat um einen hocheffizienten Magnetheizer für
die Metallindustrie, der große Mengen elektrischer Energie einsparen
hilft. Bundesumweltminister Norbert
Röttgen und BDI-Hauptgeschäftsführer Werner Schnappauf überreichten
den Preis in der Kategorie „Prozessinnovationen für den Klimaschutz“ in
Berlin an die Zenergy Power GmbH
und Bültmann GmbH, die diesen Maschinentyp gemeinsam entwickelt
haben.
Anders als normale elektrische
Leiter übertragen Supraleiter Strom
ohne Widerstand und daher auch
ohne Verluste. Maschinen und Anlagen mit Supraleitertechnik sind dadurch leistungsfähiger und verbrau-
chen weniger Strom. Das erste Unternehmen, das den Anlagentyp seit
2008 in der Aluminiumverarbeitung
einsetzt, spart damit 50 Prozent elektrische Energie ein und erzielt eine
um 25 Prozent höhere Produktivität.
Mit dem Magnetheizer stellen die
Firmen Zenergy Power und Bültmann
weltweit erstmals die Industrietauglichkeit der Supraleitertechnik unter Beweis. Aus Sicht der Industrie
spricht für das Verfahren, dass die
Erwärmung von Werkstoffen wie Aluminium oder Kupfer in einem Bruchteil der bisher üblichen Zeit abläuft
und erstmals exakt gesteuert werden
kann. Der Magnetheizer erwärmt ein
breites Spektrum von Materialien
und versorgt moderne Just-in-TimeFertigungen im flexiblen Wechsel
mit Metallen verschiedener Zusammensetzungen. Mittlerweile wurden
fünf Anlagen an europäische Kunden
verkauft.
ALUMINIUM · 3/2010
News IN BrIeF
Hydro aims for global lead on reducing climate emissions
After having already reduced direct
emissions from primary production
by 70% since 1990 – equal to a staggering three tonnes CO2-equivalents
per tonne metal produced – Hydro
aims to curb emissions even further
and take global lead in the aluminium industry within the global fight
against climate change.
The renewed push to cut direct
emissions from primary production
is important not only from an environmental perspective as aluminium
is set at 1.5 tonnes of CO2-equivalents
per tonne metal produced. With free
emission allowances for top performers when the new European emissions trading scheme (ETS) comes
into force in 2013, there will be a
strong incentive for industry players
to reduce their carbon footprint and
thereby reducing costs.
In 2009, the average emission
level of CO2-equivalents from Hydro’s fully-owned Norwegian smelters at Sunndal, Årdal, Høyanger and
Karmøy slipped just below two tonnes
per tonne metal produced, down from
around five tonnes in 1990 and 2.5
tonnes in 2000. With a total production from these smelters in 2009 of
about 740,000 tonnes, this represents
an annual reduction of 2.2 million
tonnes CO2-equivalents compared to
the 1990-level, which is equal to taking one million cars off the road.
The strong improvements have
not only come through closures of
outdated Søderberg lines, but also
through systematic work to reduce
anode effect and anode consumption.
rio tinto Alcan sees slow recovery of aluminium use
Rio Tinto Alcan is cautiously optimistic about the economic recovery, but
expects it will be three or four years
before aluminium consumption rates
return to pre-recession levels. The optimism is based on several factors, including rising consumer confidence,
industrial output, construction levels
and automotive production during
the past three quarters. Urbanization
and industrialization in countries like
India, Brazil and China will assure
long-term aluminium demand growth
of about 4% per year during the next
two decades..
But Rio Tinto Alcan has slowed
major investments in Canada, including two smelters in Quebec and one in
British Columbia valued at more than
6 billion Canadian dollars (USD5.7bn)
due to the drop in aluminium prices.
The company also will wait two or
three more quarters to see where
demand is headed before deciding
whether spending will be ramped up,
and it has no plan to make a significant restoration of the close to 10%
of production capacity curtailed in
2009.
ALUMINIUM · 3/2010
Some uncertainty also remains over
how robust the recovery will be
once government stimulus packages
around the world, which have helped
boost demand and prices for aluminium, come to an end.
In talks on big smelter
project in Paraguay
Rio Tinto Alcan and the Administratión Nacional de Electricidad
(Ande) are negotiating the terms of a
power purchase agreement for a po-
tential USD2.5bn aluminium smelter
in Paraguay with a projected capacity of 485,000 tpy. Being built this
would be one of the biggest industrial
investments in Paraguay’s history.
The smelter will only succeed if the
company secures a cheap and guaranteed power supply to compensate
for drawbacks at the site, such as lack
of infrastructure, no sea access and no
bauxite or alumina production. Construction could start in 2014 and put
on stream in 2016.
paw
Aluminium of Greece under eu scrutiny
The EU Commission is investigating
whether Greece’s state-owned Public
Power Corp. (PPC) illegally subsidised
Aluminium of Greece by selling electricity below market prices. PPC might have
undercharged a total of 17.4m euros.
The investigation comprises state-owned
Public Gas Corp. which is confronted
with the allegation of paying the construction costs of a gas pipeline belong-
ing to Aluminium of Greece. The European authority has already scrutinised
complaints that the aluminium company
received privileges before Greece joined
the EU in 1981. In July 2009, PPC sought
arbitration to resolve a dispute with
Aluminium of Greece, which refused to
accept a 10% increase in PPC’s electricity
prices, citing profitability concerns amid
a slumping metals market.
Aktuelles
Industriestrompreise weiter gefallen
VIk-strompreisindex Mittelspannung
Der VIK-Index ist im Januar 2010 gegenüber dem
Vormonat um 5,89 Punkte (-3,95%) gefallen und
liegt aktuell bei 143,39 Punkten. Die Veränderung ist auch in diesem Monat wieder auf die im
Durchschnitt (Mittelwert bei 3.000, 4.000,
5000 und 6.000 Jahresbenutzungsstunden)
gegenüber dem Vormonat um 2,74 €/MWh
(-5,42%) gesunkenen Strompreise an der
EEX für die folgenden vier Quartale 2010
zurückzuführen. Maßgeblich ist der Handelsmonat Dezember 2009.
Sowohl der Verband der Industriellen
Energie- und Kraftwirtschaft (VIK) als
auch der Bundesverbandes der Energie-Abnehmer (VEA) melden gesun-
kene Strompreise für die Industrie.
Wegen der stark gesunkenen Großhandelspreise für Strom können mittelständische Unternehmen derzeit
VAr / OeA-Druckguss-wettbewerb 2010
VAR / OEA
Der deutsche und der europäische
Verband der Recyclingindustrie VAR
und OEA haben mit Unterstützung
des Bundesverbandes der Deutschen
Gießerei-Industrie (BDG) erneut ei-
Preisträger „Türrahmen Porsche G1 Pana­
mera“. Bei diesem Gussteil handelt es sich
um die erste Serienanwendung, bei der
präzise Außengeometrien durch einen La­
serschneidprozess erstellt werden. Dieses
Verfahren führt gegenüber konventionell
gestanzten Gussteilen zu einer deutlichen
Qualitätsverbesserung.
nen Aluminium-Druckguss-Wettbewerb durchgeführt. Alle zur Bewertung vorliegenden Druckgussteile
zeichneten sich durch eine hohe Prä-
zision in der Herstellung, beste druckgießgerechte Konstruktion und hohe
Gussqualität aus.
Vergeben wurden je zwei erste
Preise und je ein zweiter Preis in der
Kategorie „Strukturteile“ und „Multifunktionale endkonturnah gegossene
Teile“.
Preisträger in der Kategorie
„Strukturteile“ sind der Heckklappentragrahmen BMW 5er Gran Turismo der BMW-Leichtmetallgießerei in
Landshut, außerdem der Türrahmen
Porsche G1 Panamera, hergestellt von
Georg Fischer im österreichischen Altenmarkt, sowie das Verbindungsteil
Schweller-Längsträger rechts Audi
A8 aus dem VW-Werk in Kassel.
Preisträger in der Kategorie „Multifunktionale endkonturnah gegossene
Teile“ sind das Fluidmanagement-Ölfiltersystem für Deutz-Motoren der
Gießerei Hengst aus Nordwalde, außerdem die Elektronische Luftaufbereitung der DGS Druckguss Systeme
aus St. Gallen in der Schweiz sowie
der Wärmetauscher für gasbefeuerte
Heizkessel von Rubitech Heating aus
Steenwijk, Niederlande.
günstige Lieferverträge
abschließen, so der VEA.
Deren aktueller Strompreisvergleich ermittelt
eine durchschnittliche
Preissenkung von knapp
zehn Prozent im Vergleich zum Vorjahr. Die
Entlastung hätte sogar
höher ausfallen können,
doch die Netzentgelte
sowie die Förderung
der erneuerbaren Energien haben einen Großteil des Preisrückgangs
wieder aufgezehrt. Die
Großhandelspreise gingen in den vergangenen
zwölf Monaten um über
26 Prozent zurück. Gleichzeitig stiegen die Durchleitungskosten um sieben Prozent und die Umlage zur Förderung der erneuerbaren Energien
um nahezu 80 Prozent. Der VEA rät
allen Unternehmen zu einer bundesweiten Ausschreibung ihres Strombedarfs, um das aktuell günstige Marktumfeld zur Strombeschaffung für das
Jahr 2011 zu nutzen.
Der aktuelle VEA-Preisvergleich
umfasst 50 große Netzgebiete in
Deutschland. Am günstigsten ist der
Strom in Kiel, am teuersten im Netzgebiet der E.ON Avacon in SachsenAnhalt. Nach wie vor ist der Preisunterschied zwischen den alten und
neuen Bundesländern gravierend. In
Ostdeutschland müssen Energieabnehmer durchschnittlich 7,8 Prozent
mehr für Strom zahlen.
Auf ein wort
„Wir müssen die Belastungen für bestimmte Branchen sehr genau im Auge
behalten. Die Aluminiumindustrie befindet sich im Moment in einer schwierigen Lage. Ich will, dass Deutschland
Industrieland bleibt. Dazu brauchen wir
komplette Wertschöpfungsketten und
auch die Aluminiumindustrie. “
Bundeswirtschaftsminister Rainer
Brüderle im Handelsblatt, 18.01.2010
ALUMINIUM · 3/2010
News IN BrIeF
Reported primary aluminium production
(Thousands of metric tonnes)
Africa
North
America
Latin
America
East &
South Asia
West
Europe
East/Central Europe
Oceania
China
Total
5,495
2,275
2,475
4,068
3,996
2,198
5,547
27,482
Year
2003
1,428
Year
2005
1,753
5,382
2,391
3,139
4,352
4,194
2,252
7,806
31,269
Year
2007
1,815
5,642
2,558
3,717
4,305
4,460
2,315
12,588
37,400
Year
2009
1,681
4,759
2,508
4,401
3,722
4,117
2,211
12,964
36,363
IAI statistics show that world production
of primary aluminium has increased by one
third since 2003, despite production cuts
due to the recent economic crisis. While
output from the Americas and Europe has
remained more or less steady over the
years, it is China and the Asian region that
have expanded primary aluminium produc­
tion. With the start­up of the Qatalum plant
and Emal smelter at the end of last year,
Aluminium due to surge
Novelis
The worldwide adoption of aluminium in industrial and consumer applications may be about to surge, says
Philip Martens, president and chief
operating officer of Novelis, a global
leader in aluminium rolled products
Current projections of aluminium demand
look too conservative, says Philip Martens
and aluminium can recycling. Mr
Martens was the keynote speaker at
the Platts Aluminium Symposium
2010 held early in February.
Rapid urbanisation in developing
countries and a push for sustainability are the drivers that will increase
demand for aluminium beyond current projections. “Beverage cans, food
packaging, appliances, construction,
transportation and personal technology all are on the verge of a new boom
in emerging markets. In transportation
alone – products like shipping containers, trucks, commuter trains and
ALUMINIUM · 3/2010
automobiles – the opportunity is bigger than most observers have recognised”, he said. Light-weighting is the
key. Without compromising strength,
aluminium allows for light-weighting
in the design of anything that moves.
In a world constrained by fuel supplies, and as alternative energy sources come online, aluminium was the
most plausible option, he said.
According to market researcher
Ducker Worldwide, the percentage of
aluminium in automobile design has
been gradually climbing for decades –
from two percent in the United States
in 1975 to a projected ten percent in
2020 – typically replacing steel components. But heightened consideration of light-weighting driven by consumer demand and government regulation could quickly change the pace
of adoption. “We may be about to see
a sharp turn in the next few years that
would make the aluminium industry’s
current projections of demand look
very conservative”, Mr Martens told
the Platts Aluminium Symposium.
“We’ve been having talks with automobile manufacturers that are more
than encouraging on this point.”
Food packaging will see a new wave
of demand as well, he is convinced.
“In just the next few years, more than
two billion people will cross the official threshold out of poverty. When
you look at the global performance of
beverage companies, it’s clear that the
capacity to manufacture aluminium
beverage containers and other food
packaging will struggle to keep pace
with demand.”
Source: IAI
Period
the Middle East – here included in ‘South
Asia’ – will become even more important
as an aluminium producer in future. Next
year’s table will show a further rise in the
‘Asia’ column.
Aleris to emerge from
Chapter 11 by mid-year
Aleris International has filed its proposed plan of reorganisation (Plan)
and related draft Disclosure Statement with the US Bankruptcy Court in
Delaware. With this filing, Aleris and
its wholly-owned US subsidiaries codebtors are positioned to emerge from
Chapter 11 protection by mid-year.
The Plan has support from Aleris’s
creditors. “Since our filing last February, we have made significant improvements to our operations worldwide, reducing overhead, manufacturing costs and global headcount.
When Aleris emerges from Chapter
11, we will have eliminated all of our
term loan and unsecured debt and
will have a strong balance sheet”, said
Steven J. Demetriou, Aleris chairman
and CEO.
Key elements of the Plan, as currently proposed and subject to approval by the Bankruptcy Court, are
among others:
• The backstop parties have committed to invest up to USD690 million in
the reorganised company, subject to
customary conditions;
• The reorganised company will
emerge from chapter 11 as a privately held enterprise majority owned by
existing creditors led by the backstop
parties, which are the largest providers of the company’s debtor-in-possession (DIP) term loan financing;
• Aleris will have a minimum of
USD233 million of liquidity through
cash and an anticipated USD500 million asset-backed revolving credit facility upon emergence.
wIrtsCHAFt
10
ALUMINIUM · 3/2010
CELL TECHNOLOGY
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 % *
Dez
44,8
-14,1
28,8
-49,7
90,7
-23,8
23,2
-25,0
Jan 09
40,6
-23,1
40,3
-43,3
108,6
-29,6
34,4
-33,2
Feb
33,9
-31,3
36,7
-47,0
117,1
-26,5
31,8
-40,1
Mrz
27,5
-47,7
45,6
-29,0
133,2
-19,9
33,0
-31,9
Apr
17,5
-65,5
40,3
-45,6
121,3
-30,8
33,1
-40,1
Mai
17,5
-66,8
45,9
-29,7
120,0
-24,6
33,6
-29,1
Jun
18,2
-64,2
48,8
-28,7
135,8
-17,3
37,5
-30,1
Jul
19,9
-61,7
51,9
-17,0
149,1
-10,6
40,9
-23,6
Aug
20,5
-60,4
43,2
-12,5
132,0
-10,4
38,1
-23,1
Sep
21,2
-57,4
55,7
-10,0
140,9
-10,6
43,4
-16,0
Okt
24,2
-52,6
55,0
-4,9
143,8
-5,8
45,7
-9,3
Nov
24,5
-48,1
55,0
14,2
149,1
20,8
45,5
12,6
Dez
26,1
-41,6
42,4
47,3
109,3
20,5
26,9
15,9
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
walzprodukte > 0,2 mm
12
sekundäraluminium
Press- und Ziehprodukte
ALUMINIUM · 3/2010
Cold Rolling Mill
Slitter
YOUR RELIABLE PARTNER IN ALUMINIUM FABRICATION AND PROCESSING INDUSTRY!
economics
Bauxite and alumina activities in 2009, Part i
R. P. Pawlek, Sierre
This review covers the events
during the year 2009. Due to the
worldwide financial crisis, many
new projects were delayed, while
other projects were slowed down
or abandoned.
AFRicA
alumina are expected in five years.
Ghana: In October, Rio Tinto sold
its 80% stake in Ghana’s only bauxite mine to Chinese minerals group
Bosai, which produces alumina and
aluminium in China. Rio had earlier
planned an integrated alumina refinery which would have been fed by the
Awaso mine, but shelved this, as a result of poor local infrastructure and
lower global demand for minerals.
The mine in the West African country produced only 637,000 tonnes of
bauxite in 2008.
Guinea: Guinea’s bauxite mining and alumina refining operations
Cameroon: In May, Dubal’s Cameroon
project was on track and is due to
start production in 2013. In October
Cameroon Alumina Ltd (CAL) had
found 550m tonnes of bauxite at the
Ngaoundal and Minim-Martap properties in the country’s Adamawa region, and there may be at
least another 200m tonnes
of first class bauxite which
can be open pit mined.
CAL is a joint venture set
up in 2008 by Dubal and
India’s Hindalco Industries, which each have
a 45% stake, along with
US firm Hydromine Inc.
which holds the remaining interest.
CAL hopes to build a
mining operation at the
site that would produce
4.5 to 9m tpy of bauxite
starting in late 2014, and
an alumina refinery with a
capacity of 1.4 to 3m tpy.
The real challenge is the
logistics problem because
the mining site is 860 km
from the port. The key is to
find an efficient and costeffective way of bringing
processed alumina to the
port for export. The company is in negotiations
with government officials
over possibly upgrading
and extending existing Bauxite conveyance railway links from the
continue without disruption followmines to the Kribi deep sea port. This
ing a military coup at the end of Dewould cost some USD5bn to build. If
cember 2008 in the bauxite-rich west
all goes according to plan, the bankaAfrican country. Nevertheless, there
ble feasibility study should be through
are still concerns about the new govin 2012 and make way for construcernment’s plans to push ahead with
tion work to begin, which will last 40
a review of the country’s mining opmonths. First shipments of Cameroon
14
erations. There was some confusion
over the status of the country’s mining contracts following comments by
the head of the military, who is acting
as Guinea’s new president, Captain
Mousse Dadis Camara. Compagnie
des Bauxites de Guinée (CBG), the
country’s largest bauxite exporter, has
not been affected by turbulence in the
country, although Alcoa, a partner at
the mine, continues to monitor the
situation.
In April, workers at Russian aluminium firm Rusal’s Friguia alumina
refinery in Guinea began a strike for
better salary. A reduced workforce
kept a minimum service
going, so the refinery did
not shut down completely,
but operated at a level
of 40% of its productivity. Friguia can produce
640,000 tpy of alumina.
Workers want the company to triple their salaries
from USD100 to USD300
per month, a demand Rusal
described as unacceptable
and economically groundless. On 8 April, UC Rusal
resumed full production
at its alumina refinery in
Guinea.
In May, Global Alumina
said it expected construction of its 3.6m tpy alumina refinery joint-venture
project in Guinea to start
within the next 18 months.
Preliminary infrastructure
is under construction at
the Global Alumina site,
while the company waits
for the global economy
to recover before seeking
more credit to fund the
building of the refinery.
Photo: Alumar
Partners in the project are
BHP Billiton, Dubal and Middle Eastern investment company Mubadala.
Political uncertainty in Guinea has not
affected Global Alumina during the
initial phases of the project and BHP’s
Guinea alumina project has been delayed due to rising costs. Building of
ALUMINIUM · 3/2010
economics
the 3.6m tpy alumina refinery is due
to start by the end of 2010.
At the end of September, it was
announced that Government revenues from Guinea’s CBG would fall
some 60% in 2010 due to lower prices
and export volumes. CBG exported a
record 13.7m tonnes of bauxite in
2008, accounting for 80% of government mining income in the miningdependent nation. The revenues from
CBG will go from USD101m in 2009
to USD38m in 2010. Alcoa and Rio
Tinto Alcan control the Halco joint
venture that owns 51% of CBG, and
the Guinean government holds the remainder. CBG’s 2009 bauxite exports
will only be around 11.3m tonnes, due
to the global economic crisis.
Guinea-Bissau: In May, Angolan
company Bauxite Angola announced
plans to build and manage a USD321m
deep-water port in Buba, the largest
city in southern Guinea-Bissau.
The port is expected to become
the gateway for Guinea-Bissau’s products. Angola Bauxite, partly owned
by the Angolan state, is developing
a USD500m project to mine 3m tpy
of bauxite in the Guinea-Bissau. The
start-up date for the mine construction project and the port were not disclosed. Bauxite Angola will also build
an alumina plant to process bauxite
in Guinea-Bissau as well as a railway
and a road linking Boe and Buba.
THe AmeRicAs
Brazil: At the end of January 2009
Novelis announced that it will cease
the production of alumina at its Ouro
Preto unit at the end of March. In future, the plant will purchase alumina
through third-parties. Other activities related to the facility, including
electric power generation and the
production of primary aluminium,
will continue unaffected. The Ouro
Preto alumina facility is a small scale
operation, primarily supplying the
plant’s own requirements. Some 290
jobs will be removed at Ouro Preto.
The remaining 800 jobs will continue
to generate taxes and contribute to the
economic and social development of
Spouts and
Stoppers
Ouro Preto.
In June, Brazilian alumina and aluminium producer Alumar expected to
conclude its 2m tpy alumina expansion by the end of November 2009.
Capacity is being increased to 3.5m
tpy from the current 1.5m tpy, at a
total investment of 5.1 billion reals
(USD2.5bn). Recently, Alumar received equipment which will enable
it to lift its seaport handling capability from 4.9m tpy to roughly 13m tpy.
The company unloads bauxite and
other raw materials in its port in São
Luis, in Brazil’s northeastern state of
Maranhão, and also ships from there
its surplus alumina output that is not
used to produce aluminium locally.
In September, Alcoa commissioned its new bauxite operations in
Juruti that are part of the Alcoa World
Alumina and Chemicals (AWAC) joint
venture with Alumina Ltd in which
Alcoa holds a 60% share. They consist of a port facility, a mine and a 50
km rail system to the port. Initial output at the mine will ramp up to 2.6
m tpy. Bauxite from Juruti will ➝
Ceramic Foam
Filters
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Drache
umwelttechnik
Drache Umwelttechnik GmbH · mail@drache-gmbh.de ·
ALUMINIUM · 3/2010
www.drache-gmbh.de
15
economics
be shipped to the Alumar alumina refinery in São Luis. Following the expansion, Alcoa Aluminio and AWAC
combined hold a 54 % share of the
refinery. The remaining share is held
by BHP Billiton (36%) and Rio Tinto
Alcan (10%). The Alcoa share of the
combined investment for the two Brazil initiatives is about USD2.2bn, and
this will place Alcoa’s overall manufacturing system in the lower quartile
on the global cost curve.
The Juruti Project will mine – and
re-vegetate – a total of 6,000 hectares
Advertisement
over a period of 40 to 60 years. For
every Brazil nut tree removed during
the mining process, Alcoa will replant
ten trees. And for every other species
of tree impacted during the process,
Alcoa will replant two trees for each
tree removed. In total, Alcoa estimates
it will plant 15 million trees over the
next 50 years in the Juruti region.
Guyana: A strike over wages and
job cuts stopped output at Guyana’s
largest bauxite mine. Workers were
resisting pressure by the company
to accept 75 layoffs in return for a
10% wage increase for the remaining workers. The mine employs 500
people. Guyana, in South America, is
the fourth largest supplier of bauxite
to the United States.
The strike at the Aroaima mine,
105 km south of the capital Georgetown, began on 22 November and
there was no immediate end in sight.
The current destructive actions by
certain employees and unions are
in violation of the collective labour
agreement and labour discipline, and
destabilise the situation among the
company’s staff.
Rusal bought the Aroaima operations from the government in 2004
through its local subsidiary Bauxite
Company Guyana Inc. Rusal’s bauxite from Guyana supplies its Nikolaev
alumina refinery in Ukraine, which
produces up to 1.7m tpy of alumina.
16
Jamaica: In February, there was a
meeting between Jamaican prime
minister Bruce Golding and Chinese
vice-president Xi Jinping, sparking
rumours that Chinese aluminium
producer Chinalco may be interested
in alumina assets in the country. The
Jamaican government is in discussions to sell its 45% stake in the 1.4m
tpy Jamalco refinery in the country, in
which Alcoa holds a 55% stake. But
the two may also have discussed the
future of Alumina Partners of Jamaica Ltd (Alpart), Rusal’s joint venture
with Norsk Hydro. Chinalco could
very well acquire Alpart, given the
possibility of further production cuts
at the operation. Alpart cut alumina
production by 50% in January 2009
to 800,000 tpy and has put employees
on a shorter working week.
On 1 April, West Indies Alumina
Co, whose majority shareholder is
UC Rusal, suspended bauxite mining as part of a plan to temporarily
shutter the Jamaican company’s operations. Windalco employs 1,119
people and produces 1.2m tpy of alumina at its two plants in Kirkvine in
the south central region and Ewarton
in the northeast. About 850 are affected by the suspension due to the
world downturn in demand, but the
company decided to keep them on the
payroll working reduced hours on a
reduced pay.
Century Aluminum Co. announced
the sale of the company’s 49% joint
venture ownership positions in
Gramercy Alumina LLC and St. Ann
Bauxite Ltd to Noranda Aluminum
Holding Corp. With the closing of this
transaction on 31 August, Century
has divested itself of its entire interest
in the bauxite and alumina businesses. In November Noranda changed
the name of its new bauxite operation
from St. Ann Bauxite Ltd to Noranda
Bauxite Ltd although the Jamaican
government still owns 51%. Noranda
Bauxite has a capacity to mine 4.8m
tpy of bauxite but is expected to produce only 75 to 80% of that capacity
in 2009.
Suriname: At the end of April, Alcoa World Alumina and Billiton Suriname Holdings reached an agreement
in principle where Suriname Aluminum (Suralco), an Alcoa subsidiary,
will acquire the bauxite and alumina
refining interests of BHP Billiton
Maatschappij Suriname (BMS), a BHP
subsidiary, in Suriname. Terms were
not disclosed. Late in July, Alcoa World
Alumina completed its transaction to
acquire BHP Billiton’s bauxite and
alumina refining interests. Suralco
has mined bauxite and refined alumina in Suriname since 1984. BMS had a
45% interest and Suralco a 55% interest in the joint ventures. Prior to the
establishment of the joint ventures,
BMS had separately conducted mining operations in the country, while
Suralco has been active in Suriname
for almost 100 years.
USA: In February 2009, Noranda
Aluminum talked with its joint-venture partner to close the Gramercy
Alumina refinery in Gramercy, La.
Gramercy Alumina is a 50:50 partnership between Franklin/Tennessee-based Noranda and Century Aluminum, Monterey/California, and it
has a nameplate alumina capacity of
1.2 m tpy, of which 80% is smeltergrade alumina.
The production cost of alumina
purchased from Gramercy exceeded
the cost of alumina available from
third-party sources, and Noranda
was evaluating the possibility of curtailing all of Gramercy’s operations.
Spot alumina prices had dropped to
about USD170 per tonne f.o.b. from a
peak of around USD430 per tonne in
early July 2008. This was troubling for
Gramercy, considering it has a higher
cost of operation due to elevated labour costs and because all of its bauxite is shipped in from Jamaica.
Gramercy is supplied by St. Ann
Jamaica Bauxite Partners Ltd. Noranda was also in negotiation with Century concerning the future of Gramercy
and St. Ann after 31 December 2010,
when their current contract expires.
Higher raw material costs, primarily
due to Gramercy, had an USD8.9m
unfavourable impact on Q4 2008 operating earnings compared with the
corresponding period a year earlier.
Because of the global downturn in
aluminium demand, Gramercy was
producing at approx. 50% of capacity. Gramercy is supplied by St. Ann
Bauxite, a mining facility in Jamaica
with a capacity of 4.8m tpy, which was
ALUMINIUM · 3/2010
economics
running at the end only at 40% of its
capacity.
In return for its equity in the mining and refining operations, Noranda
agreed to release Century from certain obligations and pay Century approximately USD10m in cash. The
deal closed by the end of August. As
part of the deal, Century entered into
an agreement to purchase alumina
from Gramercy in 2009 and 2010.
Century’s primary aluminium smelter
in Hawesville/Kentucky currently receives all of its alumina supplies from
Gramercy.
Venezuela: In February 2009, the
Los Pijiguaos bauxite mine owned
by Venezuelan bauxite and aluminium producer Bauxilum designed
to produce 6m tpy was operating at
only 50% capacity due to a shortage of input supplies that prevented
machinery from functioning normally. Infrastructure for mining and
processing Los Pijiguaos’ includes
the mine, the crushing mill, a 4.5 km
conveyor belt, a 52 km railroad and
control centre. An operational breakdown at Bauxilum would cause the
entire aluminium production chain
to collapse. Bauxilum also operates a
2m tpy alumina plant in Guayana region’s Puerto Ordaz city. State heavy
industry holding CVG controls 99% of
Bauxilum and the remainder is held
by Rio Tinto Alcan.
In October, Bauxilum signed an
agreement with state-owned development bank Bandes and the Chinese-Venezuelan joint fund to access
100m bolívares (USD46.5m) and
USD39m for the company’s recovery.
This money will be invested under
worker supervision, and with this
urgent work the plant can start to recover. The fact that workers will now
be given a say in where the funds will
be spent is the most important part of
the agreement.
The lack of investments in technology upgrades in Bauxilum has
drastically lowered the company’s
production. In September, Bauxilum
suspended part of its sales to international clients to favour local buyers. Bauxilum previously presented a
recovery plan to the basic industries
and mining ministry (Mibam) calling
for an investment of nearly USD91m
to save the company. The company
has already reduced its production
goal for this year from 1.7m to 1.4m
tonnes of alumina due to technical
and economic difficulties.
To be continued
in ALUMINIUM 4/2010
Dubal celebrates major production milestone
Dubal
Cast metal production at Jebel Ali-based smelter complex exceeds one million tonnes in 2009
Excellent reason for celebrating: Dubal’s Jebel Ali smelter produced a record of cast aluminium products in 2009
The Jebel Ali primary aluminium
complex, owned and operated by
Dubai Aluminium (Dubal), produced 1,009,772 tonnes of cast
aluminium products in 2009.
Ranked as the world’s largest
modern smelter with a captive
power station and widely regarded
as the industrial flagship of the
United Arab Emirates, the entirely
state-owned enterprise attributes
the achievement of this major
production milestone to a strate-
ALUMINIUM · 3/2010
gic focus on optimising capacity
utilisation, maximising operating
efficiencies, continuous innovation
and pro-actively meeting market
needs.
“Exceeding one million tonnes in
finished products in a single year is
a tremendous feat for Dubal – especially as an annual production volume
of 1,009,772 tonnes makes Dubal the
largest single-site aluminium producer
of value-added products in the world,
by far”, said Abdulla Kalban, the
company’s president and CEO. The
record not only fulfilled a corporate
objective in its 30th anniversary year,
but it was also achieved in the midst
of the global economic recession,
which forced many other primary
aluminium producers into a partial
close-down of production capacity.
Dubal has continued to operate at
full capacity throughout the downturn “and, as in prior years, we presold our entire production”, Mr ➝
17
economics
Kalban said. “We did this by establishing new markets for our metal, changing our product mix to meet the needs
of our customers, enhancing process
efficiencies and improving our productivity levels” – a strategic combination that enabled a 6.5 percent
year-on-year increase in cast metal
production compared to the 947,751
tonnes cast in 2008.
In general, Dubal manufactures
aluminium products in three broad
categories at Jebel Ali: foundry alloy
for automotive applications, extrusion
billet for construction, industrial and
transportation purposes and also high
purity aluminium for the electronics
and aerospace industries. The product portfolio also includes bus bars
for the primary aluminium industry (used in-house and sold to other
smelter complexes). More than 112
different products are manufactured,
the majority of which are customised
to customer specifications.
The 2009 production milestone,
set by Dubal’s casting operations,
marks the fruition of the successive
expansion projects undertaken at the
Jebel Ali site between 1990 and 2008.
Dubal’s smelting capacity has grown
from 135,000 tonnes per year since its
start in 1979 to a current one million
tonnes per annum, which is a sevenfold increase. “The capacity of our
casting operations has expanded in
parallel: from an initial 490 tonnes per
annum it has grown 159.39 percent to
a current 1,271,000 tonnes per annum
— which makes it the largest in the
world”, Mr Kalban said.
Since inception, Dubal’s casting
operations have repeatedly notched
up world-class performance achievements. The first one million tonnes of
finished products was produced in
1987, with the five millionth cumulative tonne production milestone being
reached in 2001. Just six years later,
in October 2007, Dubal manufactured
the ten millionth cumulative tonne of
finished products. In 2009 alone, several new records were set:
• The order for 40,000 tonnes worth
of anode/bus bars for the Emirates
Aluminium (Emal) potlines was completed (execution of the order began
in 2008)
• A record of 29,891 tonnes of sow
18
ingots was produced – which annualised to 359,000 tonnes
• The world record in billet casting
(in terms of maximum number of casts
per day) was achieved in April 2009,
giving an annualised casting capability of approx. 735,000 tonnes.
• A record of 14,816 tonnes was
achieved in standard ingot production
in November 2009, which gives an annualised figure of 221,000 tonnes.
Ever-ambitious, Dubal has set its
sights on an even higher cast metal
production volume of 1,024,000
tonnes in 2010 which will mean utilising 80.6 percent of the casthouse
production capacity (compared to
79.4% in 2009). Kalban added: “Our
company has a proven track record
over the past 30 years. Going forward,
we are confident that our business
model will continue to deliver further
sustainable growth.”
About Dubal
Dubai Aluminium Company Ltd owns
and operates the world’s largest modern primary aluminium smelter with a
captive power station. Built on a 480hectare site in Jebel Ali, the complex’s
major facilities comprise a one million
tpy smelter, a 2,350 MW power station, a large carbon plant, casthouse
operations, a 30 million gallon perday water desalination plant, laboratories, port and storage facilities.
The Jebel Ali serves 300 customers in at least 45 countries, predominantly in the Far East, Europe, the
Asean region, the Middle East and
Mediterranean region, and North
America. The company holds ISO
9001, ISO/TS 16949, ISO/IEC 27001,
ISO/IEC 20000, ISO 14001 and OHSAS 18001 certification at its Jebel
Ali site and has twice won the Du-
bai Quality Award in the Production
and Manufacturing sector (1996 and
2000). More than 4,100 operators,
tradesmen, administrative staff, technicians, professionals and managers
are employed by Dubal. Some 24 percent of the total workforce is drawn
from the local population, with UAE
nationals holding over 70 percent of
senior management positions.
Dubal also holds a 50 percent
share in Emirates Aluminium (Emal),
a green-field smelter development at
Al Taweelah, Abu Dhabi. Commissioning of the first phase of Emal (comprising a 756,000 tpy smelter plus associated power generation, reduction
material and casting infrastructure)
began in December 2009.
Driven by a quest for continuous
improvement and ongoing innovation, Dubal has invested substantial
sums of money over the past 25 years
in developing advanced reduction
cell technologies that not only improve productivity but also reduce
the operations’ impact on the environment through improved energy
efficiency and minimised emission
levels. This has culminated in Dubal’s
proprietary DX technology – a flagship technology that operates at 370
kA plus and therefore ranks among
the best in its class. Developed in
2006, DX technology has been implemented in a dedicated 40-cell potline
at the Jebel Ali smelter complex and
is being installed at Emal, which will
ultimately produce 1.5 million tpy.
Entirely state-owned, Dubal is one
of the largest non-oil contributors to
the economy of Dubai and is widely
regarded as the industrial flagship of
the UAE. Having begun to tap metal at
the Jebel Ali site in November 1979,
the company celebrated its 30th anniversary in 2009.
■
emal delivers to first local customer
Emirates Aluminium (Emal) has won its
first local customer Trans Gulf Aluminium
(TGA), a manufacturer of aluminium wire
rods and aluminium alloy ingots. “This
marks the beginning of what we hope
will be a long lasting relationship between our two companies. Emal is a cor-
nerstone in the UAE’s diversification strategy, but the role we play extends beyond
the work we do here at the smelter. The
aluminium we produce creates additional
downstream opportunities for other diversification projects like TGA”, said Emal
CEO Saeed Fadhel Al Mazrooei.
ALUMINIUM · 3/2010
WiRTscHAFT
Druckgussindustrie sieht chancen
für zweistelliges Wachstum 2010
Anlässlich der Euroguss-Messe
im Januar in Nürnberg gab Gerhard Eder, der Vorsitzende des
Verbandes Deutscher Druckgießereien (VDD) eine Einschätzung
der Marktsituation für die Druckgussindustrie. Nach den drastischen Einbrüchen der Branche im
vergangenen Jahr – Aluminium
verzeichnete dabei in den ersten
neun Monaten 2009 ein Minus
von 36,6 Prozent auf 235.400
Tonnen – erwartet Eder, dass die
Fahrzeugindustrie in der zweiten
Jahreshälfte wieder zulegt – zehn
Prozent seien 2010 vorstellbar. Die
Hersteller von Gießereimaschinen
erwarten dagegen für dieses Jahr
einen weiteren zweistelligen Umsatzrückgang.
Eder machte aber zugleich deutlich,
dass die Zuwachsraten der vergangenen Boomjahre auf absehbare
Zeit vorbei sind. Dies hat mit der
Wachstumsschwäche des Automobilsektors in Europa zu tun, dem mit fast
75 Prozent wichtigsten Absatzmarkt
für Leichtmetalldruckguss. Die Marktzuwächse in China und Indien werden
weitgehend in diesen Ländern selbst
gedeckt; die großen Fahrzeughersteller haben in den prosperierenden
Ländern in Fernost eigene Produktionen aufgebaut. Abwrackprämien
Die casting industry expects
double-digit growth in 2010
At the Euroguss trade fair in January in Nuremberg, Gerhard Eder,
chairman of the Association of
German Pressure Die Casting
Foundries (VDD), gave a status
report on the market situation for
the die casting sector. After a dramatic slump in 2009 – die castings
from aluminium declined 36.6
percent to 235.400 tonnes in the
first nine months of the year – Mr
Eder is confident that the automotive industry will return to growth
this year. Growth of castings could
stabilise at about ten percent, he
said. By contrast, the manufacturers of casting machinery and
equipment expect another year of
negative sales rates in double-digit
dimension.
Mr Eder emphasised that booming
growth rates of the past years were
history. The reason is obvious and
lies in the automobile sector, with
75 percent the most important sales
market for light metal die castings.
The large market growth in regions
like China and India will be covered
largely within these countries. The
big car manufacturers have set up
Die casting production by types of metal in Germany 1988 to 2008 (in tonnes)
20
their own production facilities in the
prospering Far East countries, which
hardly create job security or turnover
in Germany or Europe. Scrapping bonuses or comparable schemes at European level have made the market
even tighter. The market for mid- and
top-range cars will hardly grow disproportionately high and the demand
for commercial vehicles has slumped
drastically. “These markets will stagnate and a ray of sunshine can hardly
be detected here for 2010. However, I
do hope that the automotive industry
will start growing again in the second
half of 2010”, Mr Eder said.
He added: “From an optimistic
viewpoint, our association assumes
that the present growth of castings
could stabilise at about ten percent in
2010 in the best case. The die casting
foundries will no doubt need 2011
and possibly even 2012 to return
to the level of 2006 and 2007.” According to Mr Eder, the situation is
different for die casting foundries in
some industries that are still flourishing, such as power systems, medical
engineering and parts of the electrical industry. The declines there were
only minor – if at all, because these
industries need smaller batch
sizes, which are just right for
SME suppliers.
Though the sector was hit
hard by the crisis, it is worth
stating that the production
of die castings has grown
continuously over the past
years and decades. No other
casting process has shown
comparable dynamics. The
die casting foundries as component suppliers to car manufacturers, machinery and plant
manufacturers as well as other sectors of industry, such as
communication technology,
the furniture industry, and
the electrical and electronics
ALUMINIUM · 3/2010
economics
ALUMINIUM · 3/2010
oder vergleichbare Programme auf
europäischer Ebene, die vor allem
das Segment der Kleinwagen unterstützten, haben den Markt in Europa
enger gemacht. In der automobilen
Mittel- und Oberklasse sind ebenfalls
keine dynamischen Zuwächse zu erwarten und der Nutzfahrzeugbedarf
ist drastisch eingebrochen. „Diese
Märkte werden stagnieren, hier ist
kaum ein Sonnenstrahl für 2010 zu erkennen. Ich hoffe aber, dass die Fahrzeugindustrie in der zweiten Hälfte
2010 wieder zulegt“, so Eder.
Der Verbandsvorsitzende weiter:
„Bei optimistischer Sichtweise geht
unser Verband davon aus, dass sich
der Gusszuwachs 2010 günstigstenfalls bei etwa zehn Prozent stabilisieren kann. Druckgießereien brauchen
wohl das Jahr 2011, wenn nicht sogar
2012, um sich wieder auf dem Niveau
von 2006 und 2007 einzufinden.“ Anders sehe die Situation für Druckgießereien aus, die in weiterhin florierende Industrien wie Energietechnik,
Medizintechnik und partiell in die
Elektroindustrie liefern. Hier seien,
wenn überhaupt, nur sehr geringe
Rückgänge zu verzeichnen. In diesen
Industrien werden kleinere Losgrößen verlangt, genau richtig für kleine,
mittelständische Anbieter.
Zwar wurde die Branche von der
Krise hart getroffen, doch darf nicht
übersehen werden, dass die Druckgussindustrie langfristig kontinuierlich zugelegt hat. Kein anderes Gießverfahren kann eine vergleichbare
Dynamik vorweisen. Die Druckgießereien haben nicht nur als Zulieferer
der Automobilhersteller und des Maschinen- und Anlagenbaus, sondern
auch für andere Industriezweige wie
Kommunikationstechnologie, Elektronikbranche und Möbelindustrie
kontinuierlich an Bedeutung gewonnen. Im vergangenen Jahr beschäftigte
die deutsche Druckgussindustrie immerhin rund 17.000 Mitarbeiter in
290 Betrieben. Und der Gesamtumsatz lag 2008 bei 2,5 Milliarden Euro.
Doch nicht nur in Deutschland,
auch in Europa und weltweit entwickelt sich die Gießereibranche, und
dies meist bei deutlich günstigeren
Rahmenbedingungen als in Deutschland. Eder verweist auf den Anteil der
Personalkosten an den Gesamtkosten
(ohne Metall) in deutschen Gießereibetrieben, der bei über 50 Prozent liege. Deutschland befindet sich damit
im internationalen OECD-Vergleich
weiterhin auf dem dritten Platz bei
den Arbeitskosten.
„Belastend wirken auch die kontinuierlich steigenden Energiekosten,
die im Vergleich zu vielen anderen
Produktionsstandorten im Ausland
schlicht und ergreifend nicht mehr
wettbewerbsfähig sind.“ Die Gießereiindustrie im Allgemeinen und
die Druckgießereien im Speziellen sei
eine energieintensive Branche. Deren
Energieanteil an den Produktionskosten betrage sechs bis zehn Prozent,
beziehe man die gesamte Wertschöpfungskette in die Betrachtung mit
ein, etwa die Vorstufe der Metallerschmelzung, liege der Energiekostenanteil bei bis zu 30 Prozent.
Auch die Kostenentwicklung der
metallischen Vorstoffe für die Gießereiindustrie hat in den letzten
Jahren an Bedeutung gewonnen. Die
in den Druckgießereien einge- ➝
Sales of alloy die castings by customer groups in Germany in 2008 – in percent
Grafiken: VDD
industries have continuously gained
in importance. In 2008, the overall
turnover was 2.5 billion euros.
Mr Eder pointed out that in times
of globalisation, it would be foolhardy
not to expect that die castings could
also be manufactured abroad and at
distinctly more favourable terms than
at German locations. Therefore, it is
important to be better than the “cheap
foreign competition”. The share of personnel costs in German firms is more
than 50 percent of the total cost (without metal). In the OECD international
comparison, Germany still holds third
place in terms of labour cost.
Another issue for the German industry are the continually rising costs
of energy, which in comparison with
many other production locations
abroad are simply not competitive,
according to Mr Eder. The development of costs for metal raw materials
is another issue that has become increasingly relevant and controversial
for the industry. The metals used in
die casting foundries are usually made
from recycled scrap metal. Due to the
enormous need for raw materials of
all kinds, especially in the Asian region, this constantly leads to tremendous leaps in the prices of raw materials for the die casting sector. “If the
die casting foundries want to remain
profitable, these increases must be
passed on to the market, which is not
always easy”, he said pointing to the
car manufacturers as main customer
group which present there own costcutting programmes aimed at purchasing ‘cost-optimised’ components
– in other words, at lower prices.
The most important application
market for die cast products is, and
remains, the automotive industry.
That goes along with some risks, but
the opportunities for the sector are
greater, Mr Eder is convinced. His
explanation: die castings are an essential part of modern and efficient
cars, today and even more tomorrow.
As die casting only pays off in large
quantities, this process is especially
interesting for component products
in the automotive industry, such as
engine blocks, chassis parts, steering
and brake systems, gearbox components and housings as well as interior
parts. The persistent pressure ➝
21
WiRTscHAFT
setzten Metalle werden in der Regel
aus recyceltem Schrott hergestellt.
Bedingt durch den enormen Bedarf
an Rohstoffen aller Art, speziell im
asiatischen Raum, führt dies immer
wieder zu großen Preissprüngen bei
den Vormaterialien der Branche.
Diese müssen, wollen die Druckgießereien weiterhin rentabel bleiben,
an den Markt weitergegeben werden,
was nicht immer einfach ist. Eder
verwies in diesem Zusammenhang
auf die Automobilindustrie und den
Preisdruck, den die OEMs auf die Zulieferer ausüben.
Der wichtigste Zielmarkt für
Druckgussprodukte ist und bleibt die
Fahrzeugindustrie. Trotz der hohen
Abhängigkeit von dieser Branche
seien die Chancen hier deutlich größer als die Risiken. Druckgussteile
sind ein wesentlicher Bestandteil
moderner, leistungsfähiger Automobile. Da sich das Druckgussverfahren
erst ab größeren Stückzahlen rechnet,
ist es besonders für Zuliefererprodukte wie Motorblöcke, Fahrwerksteile, Lenkungs- und Bremsanlagen,
Getriebegehäuse und Getriebeinnenteile sowie Interieurteile interessant.
Der anhaltende Substitutionsdruck
zugunsten von Leichtbauwerkstoffen
bleibe ein wichtiger Wachstumsmotor der Aluminium- und Magnesiumgussproduktion, speziell im Druckgießverfahren.
Vor diesem Hintergrund schätzt
Eder die mittelfristigen Aussichten
für die Druckgießer positiv ein. „Wenn
wir uns auf unsere Fähigkeiten besinnen, Innovationen vorantreiben und
ingenieurmäßiges Denken wieder
verstärkt in den Mittelpunkt unseres
Handelns stellen, haben wir eine gute
Chance, die Krise zu meistern“, sagte
er. Durch die hohen Produktionsraten
in den letzten Jahren habe die Branche sich mehr und mehr auf die Optimierung der Fertigungsabläufe konzentriert und die Gießzyklen verkürzt.
Dabei sei die Weiterentwicklung des
Gießprozesses möglicherweise etwas
vernachlässigt worden. Zudem müsse
sich wieder intensiver um die Werkstoffe gekümmert, das heißt auch
Grundlagenforschung in diesem Bereich betrieben werden.
europäische Hersteller von
Gießereimaschinen erwarten
weiteren Umsatzrückgang
Gutmann Habig, Generalsekretär
von Cemafon, betonte auf der Euroguss-Pressekonferenz, dass die Gießereimaschinenindustrie 2009 durch
einen massiven Umsatzeinbruch
gekennzeichnet war, der in Deutschland rund 40 Prozent betrug. Die
Auftragseingänge waren sogar noch
stärker rückläufig. Doch auch für diese Branche scheint das vierte Quartal
2009 den Tiefpunkt markiert zu haben. Seit Beginn dieses Jahres sei ein
World machinery trade – major export nations
for die casting machinery 2007 / 2008*
22
on replacing parts in favour of lightweight materials remains a major
driving force for the production of
aluminium and magnesium castings,
especially using the die casting process.
Against this background Mr Eder
is optimistic about the medium-term
prospects for the sector. “If we turn
to our skills, push innovation and
focus on engineering thinking again,
we have a good chance of coping with
the crisis”, he said. Due to the high
production rates in the past years, the
firms had concentrated on optimising
production flows and shortening casting cycles, and had possibly neglected
improving the casting process as such.
Moreover, the industry should pay
more attention to its materials again,
that is to carry out fundamental research in this field, he concluded.
european manufacturers of
die casting machinery expect
further decline in sales
Gutmann Habig, general secretary
of Cemafon, the European Committee of the Manufacturers of Materials
and Products for Foundries, said at
the Euroguss press conference that
the European foundry machinery industry in 2009 had been marked by
a heavy plunge in sales (e. g. minus
40% in Germany) and an even larger
drop in orders received. However,
this industry too seems to have
reached its trough in the fourth
quarter of 2009. Since the beginning of this year a slight upward
trend both in Europe and in the
export business had been noticeable, he said. On the other
hand, the sector does not expect a
return to positive sales growth in
2010 but a “flattening of negative
rates” and a possible decline in
turnover of 20 percent.
Cemafon embraces the respective national associations and thus
all major manufacturers of foundry
machinery and plant, furnaces and
products for the foundry industry
in Europe. It represents the economic and technical interests of
its members worldwide, offers
information on market and technical developments and creates a
ALUMINIUM · 3/2010
economics
platform for the exchange of views at
European level. The representation
of interests encompass, among others, the harmonisation of European
safety standards under the Machinery
Directive and the creation of ‘guidelines’ for specifying technical rules
and agreements, for example on interface issues, die casting machinery
and peripheral equipment.
Cemafon represents about 160
European manufacturers of foundry
machinery with a production volume
of more than one billion euros. These
companies account for almost 90% of
the European industry’s production
volume and hold a 40% share of total
world exports. Moreover, Cemafon
represents practically all well-known
European die casting machinery
manufacturers with a production
volume of approx. 300 million euros.
Their share of total world exports is
40% too. The Cemafon export structure shows increased shares for EU27 and America, but declines in Asia,
especially in China.
■
leichter Aufwärtstrend in Europa und
im Export spürbar. Allerdings: Eine
Rückkehr zu positiven Umsatzzahlen
sei auch 2010 nicht zu erwarten. Habig sprach von einer „Abflachung der
Negativraten“ und einem möglichen
Umsatzrückgang von 20 Prozent im
laufenden Jahr.
Cemafon ist das europäische Komitee der Hersteller von Gießereimaschinen und -ausrüstungen. Als
Dachverband mit Sitz in Frankfurt
umfasst es die jeweiligen nationalen
Verbände und damit alle bedeutenden
Hersteller von Gießereimaschinen
und -anlagen, Öfen und Produkten
für die Gießereibranche in Europa.
Die Interessenvertretung erstreckt
sich auf die wirtschaftlichen und
technischen Belange der Mitgliedsunternehmen, die Aufbereitung von
Marktinformationen und technischen
Entwicklungen und den Erfahrungsaustausch auf europäischer Ebene.
Wichtige Aspekte der Interessenvertretung betreffen die Harmonisierung
europäischer Sicherheitsstandards
unter der Maschinenrichtlinie und
die Erstellung von „Einheitsblättern“
zur Festlegung technischer Regeln
bzw. Vereinbarungen, zum Beispiel
zu Schnittstellenthemen, Druckgießmaschinen und Peripheriegeräten.
Cemafon vertritt rund 160 europäische Gießereimaschinenhersteller
mit einem Produktionsvolumen von
mehr als einer Milliarde Euro. Diese
Firmen erbringen fast 90 Prozent des
europäischen Produktionsvolumens
der Branche und halten einen Anteil von circa 40 Prozent am Gesamtweltexport. Darüber hinaus vertritt
Cemafon praktisch alle namhaften
europäischen Druckgießmaschinenhersteller mit einem Produktionsvolumen von rund 300 Millionen
Euro. Ihr Anteil am Gesamtweltexport beträgt ebenfalls 40 Prozent. Die
Cemafon-Exportstruktur weist Zuwächse der Anteile in den EU-27 und
Amerika auf, in Asien und besonders
in China dagegen Rückgänge.
■
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ALUMINIUM · 3/2010
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23
ALUMINIUMrecycLINgINDUSTrIe
VAR-Vorsitzender Oetinger zu Aluminiumschrottexporten nach China:
Für die deutsche Aluminiumrecyc­
lingindustrie war das vergangene
Jahr ähnlich schwierig wie für
die meisten anderen Branchen.
Im Anschluss an die extrem ge­
ringe Produktion im ersten Quar­
tal 2009 sei die Auslastung der
Schmelzwerkskapazitäten zwar
gestiegen, habe aber im mehrjähri­
gen Vergleich weit unter „normal“
gelegen, so der Vorsitzende des
Verbandes der Aluminiumrecyc­
lingindustrie (VAR), Erich Oetin­
ger, auf einer Pressekonferenz
Mitte Januar. Inzwischen hat sich
die Nachfrage auf niedrigem Ni­
veau stabilisiert.
Schrottseparierung in einem chinesischen Betrieb – Handarbeit dominiert, was die spätere
Gussqualität gegenüber technisch unterstützter Sortierung beeinträchtigt
keine Rede sein, da unklar ist, wie
sich der Auftragsbestand in den kommenden Monaten entwickeln wird“,
erklärte Oetinger.
Die Preise für Aluminiumlegierungen seien im Zuge der allgemeinen NE-Metallhausse stärker als
zunächst erwartet gestiegen. Ob sich
das erreichte Niveau jedoch behaupten kann, bleibe abzuwarten. Oetinger
verwies darauf, dass die Londoner
Metallbörse LME, deren Aluminiumnotierungen bis zu einem gewissen
Grad als Preisreferenz dienen, derzeit
stark von institutionellen Anlegern
beeinflusst werde, sodass die LME-
Grafiken: VAR / OEA
Vorläufige VAR-Zahlen für Deutschland lassen für das vergangene Jahr
einen Produktionsrückgang bei Aluminiumgusslegierungen von mehr
als 20 Prozent im Vergleich zu 2008
erwarten. Gezielte und aufgrund von
Insolvenzen erzwungene Produktionskürzungen haben den übrigen
Schmelzwerken zeitweilig ein wenig
Luft verschafft. Aktuell, das heißt zu
Anfang 2010, hat sich die Nachfrage
auf dem erreichten Niveau stabilisiert. „Auffallend ist allerdings, dass
vergleichsweise kurzfristig geordert
wird. Von einer wirklichen Entspannung der Lage kann bisher aber noch
G. Kirchner
„Klimatische entwicklungshilfe
gefährdet Versorgung in europa“
24
Notierungen die fundamentale Marktsituation nur bedingt reflektieren. Die
Ertragslage der Schmelzhütten hängt
bekanntlich von der Spanne zwischen
Rohstoffkosten und Verkaufspreis ab.
Diese Differenz umfasst die Produktions- und Kapitalkosten sowie den
Ertrag. Der Rohstoffkostenanteil am
Verkaufspreis liegt bei rund 80 Prozent.
Zur Geschäftslage verwies der
VAR-Vorsitzende darauf, dass die
Gusslegierungsproduktion zu rund
vier Fünfteln in den Automobilsektor
geht und die Aluminiumschmelzhütten damit sehr stark von der Entwicklung dieser Branche abhängen. Mit
dem Auslaufen der Abwrackprämie
in Deutschland sind die Verkäufe von
Kleinwagen deutlich gesunken; der
Verkauf von Fahrzeugen der Mittelund Oberklasse im In-und Ausland
weist dagegen eine leicht steigende
Tendenz auf.
Durch das Recycling werden inzwischen 35 bis 40 Prozent des Aluminiumbedarfs in Europa gedeckt.
Zahlen und Fakten
2008
2009
Gusslegierungen
658.084 t 513.807 t
Desox­Aluminium
62.814 t 51.844 t
Gesamt
720.898 t 565.652 t
Tab. 1: Gesamtdeutsche Produktion von
insgesamt 14 Unternehmen mit 21 Aluminiumschmelzhütten
ALUMINIUM · 3/2010
in %
-21,9
-17,5
-21,5
S
AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e
A LPU e
M IcN II U
Recyceltes Aluminium wird in Form
von Guss- und Knetlegierungen hergestellt. Qualitativ gibt es keinen Unterschied zwischen Legierungen, die aus
Primärmetall und solchen, die aus recyceltem Aluminium hergestellt sind.
Dass trotzdem von Primär- und Sekundärlegierungen gesprochen wird,
liegt darin begründet, dass bestimmte
Legierungseigenschaften spezielles
Vormaterial benötigen. Hier ist es
dann sinnvoll, Primärmetall zur Legierungsherstellung zu verwenden.
Nettoschrottexporte
weiten sich aus
Mit Blick auf die Rohstoffversorgung
in Deutschland und Europa, wo es
kaum oder nur geringe natürliche
Rohstoffvorkommen für Aluminium
gibt, hob Günter Kirchner, geschäftsführendes Vorstandsmitglied des VAR
und Generalsekretär der OEA (Organisation of European Aluminium Refiners and Remelters) die wachsende
Bedeutung des Aluminiumrecyclings
hervor, auch vor dem Hintergrund
„knapper, vor allem aber teurer
Energie“. Er verwies zudem auf die
positiven Umwelt- und Klimaschutzeffekte des Aluminiumrecyclings.
Rohstoffsicherheit und Klimaschutz
seien daher „gute Gründe für den
Gesetzgeber, richtige Rahmenbedingungen für den Fortbestand dieser
Industrie in Deutschland und Europa
zu schaffen. Hierzu gehören vor allem
die Beseitigung der umweltbedingten
Wettbewerbsverzerrungen und der
zahlreichen Handelsbarrieren.“
Kritisch sehen beide VAR-Sprecher, dass Jahr für Jahr mehrere
Hunderttausend Tonnen Aluminiumschrott Europa in Richtung China und
Indien verlassen. Die Versorgungsstrategie beider Länder schließt ➝
Gutachten im Auftrag der Scholz Aluminium GmbH
cO2-emission der Sekundärroute beträgt nur vier Prozent der Primärroute
In einer Zeit steigender Energiekosten
kann recyceltes Aluminium seine größte
Stärke ausspielen. Schließlich werden zur
Herstellung hochwertiger Aluminiumlegie­
rungen aus Aluminiumschrott bis zu 95
Prozent weniger Energie benötigt als zur
Primärmetallerzeugung. Damit lässt sich
die gesamte Energiebilanz des Werkstoffs
Aluminium spürbar verbessern. Auch ein
Blick auf die CO2­Bilanz von Recycling­
aluminium lohnt sich. Bedingt durch den
niedrigeren Energieeinsatz ist die CO2­
Emission deutlich niedriger.
Holger Ellmann, Geschäftsführer der
Scholz Aluminium GmbH, stellte auf der
VAR­Pressekonferenz eine vergleichende
Bewertung der Primäraluminium­Metal­
lurgie mit der Produktion von Sekundär­
aluminium am Standort Deutschland vor,
die vom Ingenieurbüro SHN durchgeführt
wurde. Die Studie zeigt auf, dass die
Sekundärroute nur etwa vier Prozent der
Kohlendioxidemissionen im Vergleich zur
ALUMINIUM · 3/2010
Primärroute verursacht. Die Berechnung
der CO2­Bilanz für die Scholz­Tochter
Alustockach GmbH wurde Ende 2009 mit
den Verbrauchszahlen für 2008 durch­
geführt und ist somit hochaktuell. Für
die Betrachtung der Primärmetallurgie
wurden Vergleichswerte herangezogen,
die den Stoffeingang der Tonerde bis
hin zum endgültigen Produkt einer
deutschen Aluminiumhütte in den Blick
nehmen. Logistik und Erzgewinnung
wurden nicht betrachtet. Für die Pro­
duktion in der Sekundärroute wurde die
Lagerung der Schrotte, die Aufbereitung,
das Zusammenstellen der Chargen, das
Schmelzen, die Auslieferung der Blöcke
und Barren bzw. des Flüssigaluminiums
herangezogen.
Basisdaten des durchgeführten
Vergleichs sind eine OEA­Studie, wo­
nach der Primärenergiebedarf für die
Gewinnung von Aluminium aus Tonerde
93,7 Gigajoule pro Tonne Aluminium
(GJ/t Al) beträgt; die Gewinnung aus
Schrotten geht dagegen mit lediglich
6,4 GJ/t Al einher. Die CO2­Intensität für
die Primärroute liegt nach Angaben der
OEA bei 10,9 t CO2/t Al für Deutschland,
in Gesamteuropa beträt sie wegen eines
günstigeren Energiemixes dagegen nur
6,2 t CO2/t Al (mehr Strom aus Wasser­
kraft in Norwegen und Kernenergie in
Frankreich). Die CO2­Emisssionen für die
Sekundärroute liegen nach Berechnungen
des Ingenieurbüros bei 0,4 t CO2/t Al für
die Alustockach GmbH und den Energie­
mix in Deutschland.
Diese Ergebnisse, so Ellmann, stützen
die politische Forderung nach Befreiung
der Sekundärhütten vom Emissions­
handel in der dritten Handelsperiode
(Befreiung von den indirekten Kosten des
Klimaschutzes bzw. der CO2­Anteile beim
Strompreis) sowie nach einer Gleichbe­
handlung mit den Primärhütten bei der
Subventionierung der Strompreise.
25
ALUMINIUMrecycLINgINDUSTrIe
den Aufbau einer eigenen Recyclingindustrie ein. Da das Aufkommen an
Aluminiumschrott aber noch gering
ist, wird dem Import hohe Priorität
eingeräumt, begleitet von einer Abschottung der heimischen Märkte
und einem vielfältigen Förderpaket
zur Einfuhr von Metallschrotten.
Vor diesem Hintergrund lag der
Nettoschrottexport der EU15 im
vergangenen Jahr bei rund 830.000
Tonnen. Allein nach China wurden
550.000 Tonnen verschifft, mehr als
doppelt so viel wie 2008. Zwar kann
zurzeit noch genügend Aluminiumschrott in der EU generiert werden,
um die heimischen Schmelzhütten
zu versorgen. Angesichts des ungebremsten Schrottbedarfs Chinas
und in zunehmendem Maße Indiens
drohe jedoch irgendwann in Europa
der Ausverkauf, wenn nicht frühzeitig gegengesteuert wird. „Man könnte
sich über diese Form der klimatischen
Entwicklungshilfe freuen, wenn nicht
gleichzeitig hierdurch die Gefahr der
Unterversorgung in Europa steigen
würde“, so Oetinger.
Seit dem Jahr 2002 ist die EU in
wachsendem Maße Nettoimporteur
von Aluminiumschrott. Temporär ist
es hierdurch bereits zu Versorgungsengpässen gekommen. Da der globale
Metallschrotthandel auf Basis des USDollars abgewickelt wird, stellt der
Euro-Wechselkurs zumindest in den
Euroländern noch eine gewisse Barriere gegen den übermäßigen Schrott-
abfluss dar. Da die natürlichen Rohstoffvorkommen in der EU sehr gering
sind – die Bauxitgewinnung lag 2008
bei 2,8 Mio. Tonnen (weltweit 216
Mio. t) – ist Aluminiumschrott mit
einem Gesamtaufkommen von knapp
5 Mio. Tonnen die wichtigste in der
EU direkt verfügbare und sichere
Rohstoffquelle.
Positiv hob Kirchner hervor, dass
die Politik zunehmend die Bedeutung
einer eigenständigen Rohstoffpolitik
für Europa entdecke, so dass auch von
politischer Seite mit mehr Unterstützung bei der Sicherung heimischer
Rohstoffe, zu denen auch Schrotte zu
zählen sind, gerechnet werden kann.
„Wir setzen hier einige Hoffnung auf
die von der EU-Kommission auf den
Weg gebrachte Raw Material Initiative“, sagte Kirchner. Diese Initiative
anerkennt die Bedeutung einer Politik
der Rohstoffsicherung für Europa in
einem globalisierten Wettbewerb um
Ressourcen. Mit diesem Ansatz wird
auch die Bedeutung eines „Level Playing Field“, das heißt eines internationalen Wettbewerbs unter gleichen
Rahmenbedingungen für europäische
Unternehmen stärker als in der Vergangenheit von Brüssel anerkannt.
Unklar ist jedoch noch, wie sich
diese grundsätzliche Neuorientierung
in konkrete Maßnahmen niederschlagen wird. Mit Blick auf den CO2-Emissionshandel in der dritten Handelsperiode ab 2013 hat Brüssel die Forderung der Branche, Sekundäraluminium aus Umwelt- und Klimaschutzgründen aus dem Emissionshandel
komplett herauszunehmen, schon vor
einiger Zeit abgelehnt. Schmelzwerke
werden damit wie normale Industriebetriebe eingestuft und ab 2013 dem
Emissionshandel unterworfen. Ein
Ausweg für die Branche könnte die
Ausnahmeregelung unter dem Stichwort „Carbon Leakage“ sein, die dann
Außenhandel
2008
Gusslegierungen
Import
Export
Aluminiumschrott
Import
Export
2009
486.298 t 452.661 t -6,9
171.320 t 146.632 t -14,1
543.868 t 351.183 t -35,4
702.754 t 742.812 t +5,7
Tab. 2: Außenhandelsbilanz 2008 und 2009
sowie Veränderungen gegenüber dem
Vorjahr
26
in %
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greift, wenn ein erhebliches Risiko zu
Produktionsschließungen und damit verbunden zu einer Verlagerung
von CO2-Emissionen in Länder mit
weniger strikten Klimaschutzbestim-
recycLINg INDUSTry
mungen besteht. In welchem Umfang
eine solche Ausnahmeregelung letztlich umgesetzt wird, dazu hat Brüssel
aber noch keine abschließende Position bezogen. Der VAR fordert für
seine Branche vollständig kostenfreie
Emissionsrechte. Entsprechendes gilt
für die in der Diskussion befindliche
CO2-Steuer für die emittierenden
Unternehmen, die nicht vom Emissionshandelssystem erfasst werden.
Hier fordert der VAR für den Fall
der Einführung einer CO2-Steuer die
vollständige Steuerbefreiung dieser
Unternehmen.
Darüber hinaus plädiert die Branche für die Beibehaltung des Einfuhrzolls von sechs Prozent auf Aluminiumlegierungen. Diesen Zoll zu reduzieren oder aufzuheben würde zu
weiteren Wettbewerbsverzerrungen
führen. Hierzu zählt der VAR das
bestehende Ungleichgewicht beim
Umweltschutz zwischen EU-Staaten
und einigen Nicht-EU-Staaten sowie
Handelsbarrieren wie Exportzölle für
Aluminiumschrotte in einer Höhe, die
Exportverboten gleichkommt; hier
hat die Branche besonders Russland
und die Ukraine im Blick.
■
Scrap exports to china threaten supplies in europe in the long term
Market needs in Europe are now covered
to an extent of 35 to 40 percent by the
recycling of aluminium. But for Europe’s
raw material supplies and for environmental and climate protection as well,
aluminium recycling is becoming increasingly important. According to Günter
Kirchner, General Secretary of the OEA
(Organisation of European Aluminium
Refiners and Remelters) these are good
reasons for Brussels to set the correct
framework conditions to ensure that this
industry has a future in Europe. In midJanuary, speaking to a group of journalists he advocated the elimination, above
all, of environment-related distortion of
competition and of the numerous trade
barriers that exist.
Kirchner regards it as critical that year
after year huge quantities of aluminium
scrap leave Europe for China and India.
Net scrap exports from the EU-15 last
year amounted to some 830,000 tonnes
of which 560,000 tonnes were shipped to
China alone, more than twice as much as
in 2008. It is true that at present enough
aluminium scrap can still be generated
in the EU to keep up supplies to the
ALUMINIUM · 3/2010
domestic smelters, but such unrestricted
demand from China and to a growing
extent India as well will sooner or later
threaten to deplete what Europe has for
sale, unless controls are established well
in time.
Since 2002 the EU has been increasingly a net importer of aluminium scrap.
Some temporary supply problems have
already arisen because of this. Since the
global trading of scrap metals is based
on the US dollar, the euro exchange rate
still forms something of a barrier against
excessive scrap outflow, at least in the
countries of the eurozone. Granted that
the availability of natural raw material
resources in the EU is very limited – for
example, in 2008 bauxite extraction was
around 2.8 million tonnes compared with
216 million tonnes worldwide – aluminium scrap, with a total output of some
five million tonnes, is the most directly
available and secure raw material source
in the EU.
Kirchner regards it as positive that in
Brussels the importance of a European
raw materials policy is being recognised
more and more, so greater support can
be expected from the political side for
safeguarding domestic raw materials, including of course scrap. It is still far from
clear, however, how this fundamental
change of attitude will be reflected by
concrete measures.
As regards CO2 emission trading in
the third trading period beginning in
2013, for environmental and climate protection reasons some time ago Brussels
rejected the call to exempt the secondary
aluminium sector completely from emissions trading. Thus, melting plants are
classified as ordinary industrial operations
and will be subject to emissions trading
from 2013. The sector is hoping for a
‘Carbon Leakage’ exemption regulation
which would come into force in the
face of a considerable risk of production
shutdowns and the associated relocation
of CO2 emission-producing activities to
countries with less strict climate protection provisions. Concerning the extent to
which such an exemption regulation will
ultimately be implemented, Brussels has
not yet adopted any firm position. The
aluminium recycling industry is calling for
completely cost-exempt emission rights.
27
ALUMINIUM recycLINg INDUSTry
Secondary aluminium smelting activities in 2009
Rudolf P. Pawlek, Sierre
The secondary aluminium busi­
ness has suffered many bank­
ruptcies in 2009. The primary
industry’s failure to cut production
to match demand exaggerates the
market loss for recycling indus­
tries. Many companies have gone
into bankruptcy through lower
of sales volume and value. Banks
have bankrupted many others by
withdrawing their existing credit,
even when they are still able to
pay their costs and interest on
loans. The recession has again hit
European and North American
firms particularly hard, due to
their higher expenses for labour,
fuel, and environmental protection.
The AMerIcAS
Canada: In January 2009, Agor aluminium smelting filed for court protection from creditors and looked for
a buyer for its plant in Bécancour,
Quebec. The high-technology mill of
Montreal-based Alsa Services Canada
Inc., Agor’s Canadian subsidiary, with
its proprietary technology for handling salt cake, shut down temporarily in mid-December 2008. Awaiting
renewed demand, no date has been
specified for reopening. However, Alsa’s sophisticated Bécancour operation continues to recover recyclable
substances from dross leftovers from
aluminium smelting, and hopes to set
up a similar US facility in Kentucky
or an adjacent state. Agor processes
salt cake to recover salt flux, used in
aluminium furnaces and the source
of eventual salt cake, as well as are
aluminium, ammonium sulphate and
a fine-grained mineral substance with
aluminium oxide predominating.
USA: General Aluminum Manufacturing Co. announced the closure of
its Richmond/Virginia plant in March
2009. The duration of the idling is
unknown, but the plant would reopen when conditions improve in the
automotive sector. The plant operated in Richmond for 17 years. The
company is owned by Park-Ohio
Holdings Corp., Cleveland. It has six
28
manufacturing plants, mostly in Ohio
and Indiana. It supplies General Motors and Chrysler.
Aluminium wheel supplier Superior Industries International Inc. announced the closure of its manufacturing facility in Van Nuys/California,
in an effort to further reduce costs
and more closely align its capacity
with sharply lower demand for light
vehicles. The company has sufficient
capacity at its remaining five plants in
North America and at a joint venture
in Hungary to accommodate current
and expected production requirements. The move eliminates approx.
290 jobs, representing 9% of Superior’s total work force, and saves about
USD16.5m in annualised labour costs.
The plant closure will likely be complete by the end of June 2010. The net
book value of manufacturing equipment and related fixed assets at the facility was about USD17.4m. Superior
is one of the world’s largest suppliers
of cast and forged aluminium wheels
for the car industry, with nine facilities in the US, Mexico and Europe.
KB Alloys Inc. completed a USD2m
expansion of its Henderson/Kentucky plant. The equipment installations were primarily focused on an
upgraded strontium pre-alloy metal
production plant, bar casting centres
and conforming equipment used to
produce ingot, bar, rod and coiled rod
products for the aluminium industry.
The new plant produces primarily a
range of aluminium-strontium alloys
such as 5Sr, 10Sr and 15Sr in 9.5 mm
diameter cut rod and coiled rod and
2.2 cm diameter Korrect Bar forms.
KB Alloys manufactures aluminium
grain refiners, hardeners, master alloys and custom-engineered materials at facilities in Henderson, Reading
and Wenatchee.
Automotive aluminium and magnesium die caster Contech LLC filed
for Chapter 11 bankruptcy protection at the end of January 2009 due
to unprecedented lows in the North
American automotive industry. The
restructuring will provide necessary
relief from significant debt, and it
will involve selling certain non-core
operations. Contech has belonged to
Marathon Automotive Group. The
company said it will not conduct an
open auction for the assets but entertain other bids until the court approves the sale to Revstone. Contech’s
casting unit has six facilities in the
US. The proposed purchase price for
the casting assets was USD14m, with
Revstone assuming certain Contech
liabilities. Revstone had no plans to
close the casting plants, and the wages
and benefits of currently employed
workers were substantially comparable to what Contech pays. The company was also looking to divest UK
subsidiary Contech Operating UK Ltd,
which operates a plant in Welshpool,
Wales. Contech UK is a stand-alone
operation in terms of cash flow and
is not a debtor in the US bankruptcy
filing. However, in order to maximise
the value of its estate, Contech is looking to sell its 100% share of Contech
UK to Hicorp Ltd, a company registered in England and Wales formed by
and comprised of the management of
Contech UK. Hicorp has agreed to pay
£2.75m (USD4.3m). The deal required
court approval.
In February 2009, Aleris International Inc., producer of aluminium
rolled products, extrusions and recycling, filed for bankruptcy protection
for its US operations. The operations
in Europe, Asia, South America, Mexico and Canada were not included in
the voluntary reorganisation filing
under Chapter 11 of the US Bankruptcy Code. Aurora Acquisition
Holdings Inc holds a 100% equity
stake in Aleris. Aurora is completely
owned by private equity group TPG.
To fund its global operations during the restructuring, Aleris secured
USD1.075bn of debtor-in-possession
(DIP) financing. Subject to court approval, the DIP credit facilities include a new USD500m term loan and
a USD575m revolving credit facility
that replaces the company’s previous
revolving credit facility. The credit
facility will be used for normal operating and working capital require-
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ments, including employee wages
and benefits, supplier payments, and
other operating expenses during the
company’s reorganisation.
Auto supplier Hayes Lemmerz International Inc. has filed for Chapter
11 bankruptcy protection, while another Tier 1 supplier, Visteon Corp.,
warned that it is on the verge of bankruptcy. Northville/Michigan-based
Hayes, which manufactures steel
and aluminium wheels for passenger cars and light trucks, commercial
trucks and trailers, as well as powertrain components, listed total assets of USD1.34bn and total debt of
USD1.4bn. The company has already
secured DIP financing to continue
operating under a pre-negotiated restructuring plan that involves no interruption in supply to its customers.
The DIP lenders will make up to USD100m available in added liquidity.
The Chapter 11 filings were precipitated by an unprecedented slowdown
in industry demand and a tightening
of credit markets. These filings will
allow Hayes to reduce its debt and
restructure its balance sheet.
At the beginning of June, Worthington Industries Inc. has bought
the assets of Piper Metal Forming
Corp., a manufacturer of aluminium
high-pressure cylinders, and two
related businesses. Piper, with one
manufacturing location in New Albany/Mississippi, also makes extruded
steel and aluminium parts for use in
the medical, automotive, defence and
oil services markets, among other industries.
Also included in the deal are US
Respiratory Inc., which assembles
and distributes Piper’s medical cylinder products, and Pacific Cylinders,
which provides distribution services
on the West Coast. Worthington did
not say how much it paid, but Piper’s
revenues were about USD30m in the
most recent calendar year.
J.L. French Automotive Castings
Inc. filed for Chapter 11 protection on
13 July in response to US automotive
production declines and to industrywide credit restrictions. The Sheboygan, Wisconsin-based aluminium automotive components manufacturer
also plans to reduce its secured debt
to USD65m from about USD280m. It
ALUMINIUM · 3/2010
recycLINg INDUSTry
will do this through debt-for-equity
swaps with first- and second-lien term
loan lenders in an effort to provide a
stable financial foundation for its operations. J.L. French and its domestic
affiliates will complete a pre-negotiated restructuring under its Chapter
11 filing in the US Bankruptcy Court
for the District of Delaware. None of
the company’s foreign operations are
included. J.L. French already has a
USD15m DIP facility to fund working
capital needs that might arise during the reorganisation. It expects to
emerge from Chapter 11 within 90
days.
At the end of July, Aleris International Inc. recalled more than 100
aluminium workers at its specification alloy and recycling plants in
Coldwater and Saginaw/Michigan,
Steele/Alabama and Morgantown/
Kentucky. The ingot casting section
of the sheet mill in Lewisport/Kentucky recalled for 25 people, partly
due to increased activity and partly
to replace retirees. Aleris is reorganising under Chapter 11 court protection. Aleris agreed to spend USD4.2m
at 15 aluminium plants to reduce air
emissions, according to the terms
of an agreement with the federal
Environmental Protection Agency
(EPA). The settlement also included a
USD4.6m civil penalty, although the
EPA accepted the status of unsecured
creditor in the Chapter 11 bankruptcy
case covering Aleris’ U.S. operations.
Negotiations had been ongoing for so
long that the deal did not include two
plants that Aleris purchased in 2007
from Wabash Alloys LLC. The ➝
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ALUMINIUM recycLINg INDUSTry
EPA examined one Aleris plant and
cited problems, but the company suggested to the EPA that a settlement be
negotiated that would involve all of
the company’s facilities, whether or
not they had violations or had been
scheduled for inspection.
Sapa announced the closure of
its Morris/Illinois aluminium extrusion plant by November. The plant
has not been profitable for several
quarters and is now redundant due
to Sapa’s recent USD151m purchase
of bankrupt aluminium extruder
Indalex Holdings Finance Inc. The
direct available UBCs to the lowestfreight-cost recycling facility. That
leaves it to the joint venture whether
a particular scrap purchase will go to
a Novelis location or one belonging
to Alcoa.
At the beginning of September,
Metal Exchange Corp. (MEC) acquired the assets of bankrupt aluminium disk manufacturer Element
Aluminum LLC, positioning the diversified nonferrous metals company
to expand its domestic fabrication
capabilities. St. Louis-based MEC, a
supplier, processor, purchaser and
for ¥4.5 billion (USD50m) in sales in
2014. In July 2008, Daiki and a Guangdong firm launched a joint venture
to make secondary aluminium alloy.
Half of the entity’s output is sold to Japan by Daiki, with the remainder sold
in China by the local partner.
But Daiki has decided it will also
conduct its own Chinese sales operations, while at the same time boosting the venture’s capacity to around
100,000 tpy. Daiki’s offtake will be
around 60,000 to 70,000 tonnes, of
which it aims to sell about 50 to 60%
to the Chinese market, with the rest
exported to Japan and other regional
markets such as Southeast Asia.
ALUMINIUM
eUrOPe
The new recycling furnace at Alunorf in Germany
operation’s casthouse produces 220,
254 and 440 mm diameter aluminium
logs in six different alloys. Its two extrusion presses have the capacity to
produce 91 tpd of aluminium profiles.
The plant’s customers include automotive, truck trailers and electronics
companies as well as assorted OEMs
and service centres.
A new Novelis-Alcoa joint venture, Evermore Recycling LLC, was
announced on 24 August. Atlantabased Novelis is 55% owner. Evermore, based in Nashville, will act
as purchasing agent for scrap going to Novelis and to Alcoa rolling
mills. Nashville is roughly midway
between an Alcoa plant in Tennessee and a Kentucky mill of Novelis,
which is part of India’s Hindalco Industries Ltd. Evermore began setting
up purchases by October, but scrap
shipments under the new setup will
not be taken until January. Since one
of the joint venture’s purposes is to
improve efficiency, the company will
30
market maker for the nonferrous industry, purchased Element’s Jackson
facility through its affiliate ElementAl
Holdings LLC for USD1.43m in cash,
plus a USD870,000 credit bid and a
USD170,000 note. Element filed for
Chapter 11 bankruptcy in July amid
financial difficulties. Production at
the Jackson facility was not disrupted
during the bankruptcy or transition
and will continue unchanged as MEC
spends the next four to six months updating equipment and systems at the
site, which employs some 30 people.
ASIA
In December 2009, Japan’s Daiki
Aluminium Industry ramped up its
secondary aluminium alloy output
in China by 150% to supply Japanese
automakers and other manufacturers in China. Japan’s largest secondary aluminium producer, Daiki Aluminium will also set up a new sales
unit in China, from which it is aiming
The proportion of aluminium beverage cans recycled in Western Europe
rose to 61.8% in 2007 from a yearearlier 57.7%. A similar calculation
for the United States that year tallied
53.8%. The European improvement
was spearheaded by Sweden, with a
six-point gain from 85% to 91%. Sweden has a refundable deposit fee, collected when beverages are sold. Other
gains of 4% or more raised Spain to
57% recycling rate, the UK to 52%
and Italy to 53%. Sorting and recycling technologies, if they separate
aluminium cans effectively, achieve
payback promptly even in a difficult
economy. Sweden’s gain to 91% catapulted that country into a tie for first
place with Germany and Belgium. At
the low end were Portugal (31%) and
Greece (36%). Annual can consumption figures for Eastern Europe also
showed growth. However, there are
no statistics to provide annual snapshots of recycling rates in that part of
the continent.
France: French aluminium recycler Sobral, which recently took over
Société Nationale de Revalorisation’s
(SNR) plant in Premery, went into receivership in April. The company was
hit by the demise of French foundry
Rencast, which went into liquidation
in March. Sobral bought SNR to supply Rencast, and after that its debt was
so great the company had no choice
but to stop. Sobral had been buying
struggling operations in France over
the past six to seven years, and until
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now it has been successfully putting
them back on track. It acquired SNR
for €500,000 in October after SNR
was liquidated in June 2008.
Germany: In March, aluminium
casting alloys producer Metallhüttenwerke Bruch filed for administration
as conditions in the European alloy
market deteriorate. The company
was forced into administration late in
February. Although in administration,
Bruch continues to produce alloy. The
company blamed its problems on the
deterioration of the automotive industry, with a drop in orders of more
than 30%.
Asperg had intended to build a
new plant at Marbach and close its
Asperg smelter, but then abandoned
this plan, overhauling Asperg over the
last few years as part of a modernisation process instead.
German die caster Metal Technologies Kitzingen (MTK) filed for preliminary insolvency at the end of April
and an administrator was appointed
to the company. MTK has capacity
of 79,000 tpy of gray and ductile iron
castings and aluminium alloys, according to a March 2008 company
presentation. MTK, formerly known
as Sachs Giesserei, was running at
about 60 to 70% of capacity because
of weak market conditions. There are
no problems at the plant – it is still in
operation.
In June, Spanish recycler Befesa
agreed to buy two insolvent German
salt slag recycling companies, Aluminium-Salzschlacke Aufbereitungs
GmbH and Alsa Süd GmbH, from
Agor AG for €23.4m. The assets comprise three production plants in the
German municipalities of Hannover,
Lünen and Töging, with combined
treatment capacity of 380,000 tpy of
waste. Befesa has two plants for recycling salt slag, one in Valladolid,
Spain, and the other in Wales, UK,
with combined capacity of 230,000
tpy. Commerzbank provided the
external financing for the deal, and
Befesa has been advised by Lincoln
International investment bank.
In November, Hydro opened a new
50,000 tpy remelting facility at the
Alunorf plant in Neuss. It is a twinchamber furnace. This brings Hydro’s
total recycling capacity in Germany to
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recycLINg INDUSTry
150,000 tpy of high-quality aluminium, and helps to reduce carbon emissions. The third furnace within three
years has been built as part of the
new recycling centre at Alunorf, the
world’s largest aluminium remelting
and rolling facility, which is a 50/50
joint venture between Hydro and
Novelis. The new €16.6m investment
makes the Alunorf plant more versatile and viable, adding recycling to the
portfolio of activities, which focus on
sheet ingot casting for subsequent hot
and cold rolling. The Hydro recycling
facility saves energy also by burning
lacquer, as attached to the scrap metal, and directly using the emerging gas
to power the remelting process. The
centre stands out with its numerous
environmental features, such as a regenerative combustion system, most
modern cleaning of exhaust gas, the
complete re-utilisation of process remains, and indoor scrap handling.
Italy: At the end of June, Italian secondary aluminium producer Fonderie
Riva suspended output until the end
of the summer due to poor market
conditions. Low volume orders and
high raw material prices prompted
the company to take this decision.
The company produces both secondary and primary ingot for casting. It
has total capacity of 25,000 tpy.
Latvia: Latvian aluminium alloy
producer Dilers opened its new 16,000
tpy plant early in May and plans to capitalise on new contracts it has picked
up since the market downturn. Dilers
is confident that its new plant will be
successful despite producers closing
down elsewhere, having kept its ➝
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ALUMINIUM recycLINg INDUSTry
production levels at 100% throughout
the economic decline. The new plant
produced two loads of material since
its inauguration, while some fine tuning takes place. About 35 people will
be employed at the facility once it is
in full production. Dilers will continue
to produce its current grades of aluminium ingot, such as DIN226, 231,
230 and 239, but will also be able to
supply 500 to 700 tpm of liquid aluminium. The new plant includes three
new reverberatory furnaces and cost
about USD6.6m to build. Construction began in July 2008, four months
later than expected because of administrative delays.
Spain: In June, Spanish aluminium
recycler Aluminsa-Aluminio Sala,
which filed for Spain’s version of
Chapter 11 debt protection in March,
reported it is seeing the benefits of
measures it has taken to improve its
efficiency and cut costs. The restructuring is already having a positive effect on the company’s balance sheet.
Aluminsa continues to operate at
about 75% of capacity.
UK: In January 2009, aluminium
recycler RecovCo-Affimet went into
administration because of difficult
market conditions. The plant in
Compiègne, France, has suffered from
poor demand, in particular from the
automotive industry. RecovCo-Affimet was Europe’s largest aluminium
recycling company, producing 70,000
tpy of material. Under Alcan, it produced 90,000 tpy. Its capacity was
increased from 55,000 tpy in January
2008 after a second tilting furnace
was installed at the plant.
UK aluminium ingot producer MilVer Metals halted production for the
first week of February to reflect a lull
in demand.
In May, W Howarth Metals mothballed the furnace at its new foundry
and will not reopen it until the economic climate improves. The company, which was bought by One51 in
February 2008, had already stopped
aluminium alloy production at its
current operations in preparation for
the move to a new three-acre site in
June. Its new premises in Ardwick,
Manchester, will open as planned and
the company will continue its scrap
metal trading business from there.
32
But the new furnace, in which the
company has invested substantially,
will not be commissioned until the
market improves. W Howarth Metals
employs about 35 people. According
to the company, its former furnaces
could melt, refine and cast 8,000 tpy
of scrap aluminium. It produced silicon aluminium ingot, and was able to
produce more than 50 specified international alloys.
At the beginning of June, automotive aluminium die caster Contech
Operating UK, a subsidiary of bankrupt Contech LLC, has been bought
out for an undisclosed sum by a management team, headed by incumbent
managing director Peter Radcliffe. The
other management members involved
in the buyout were Keith Brown, Mark
Simpson and Carl Kitley. Contech is
a primary supplier of high pressure
and squeeze cast components, both
machined and in the raw state, and
it buys about 500 tpm of material.
In September, Contech Operating
UK changed its name to Castalum
following the management buyout.
The company is moving into a new
product range and machining under a
planned investment programme.
Leeds-based aluminium die caster
Thomas Brothers closed in October
as a result of falling demand for its
products and a loss of customers. The
gravity die casting company specialises in the manufacture of high-quality aluminium castings for general and
automotive industries, and has over
35 years experience in the industry.
The company employs about 27 people. Demand for secondary aluminium die castings has fallen because
of declining business from key consumers in the worldwide automotive
industry.
In November, Evans & Reid Alloys
contemplated expansion by bringing
a third party into the company. The
Wolverhampton-based company produces between 4,800 and 6,000 tpy of
high-grade secondary- and primarybased aluminium alloys including
LM6, LM25 and L99.
conclusions
As in previous recessions, the secondary aluminium industry has suffered
even more in volume, in price and
in liquidity than the primary industry. The primary smelters are very
expensive to start and stop, and they
are capital intensive. This means they
tend to continue to sell metal at below cost price for some time, delaying amortisation and dividends. This
surplus primary metal exaggerates the
loss of sales volume and value for secondary smelters, which have a higher
proportion of variable costs that they
must continue to pay: labour, fuel, environmental protection expenses and
interest on loans.
Even when secondary businesses
are still able to pay these costs, banks
have pushed many of them into bankruptcy by withdrawing existing credit
arrangements. This seems again unfair, in view of the very low interest
rates at which governments now lend
to banks to support businesses, and at
which the banks lend to speculators
in dormant primary aluminium ingot.
These problems raise questions on
financial market structure as well as
on global environmental emissions
rules and expenses. International
government action is needed mitigate
these problems. The London Metal
Exchange needs rules to link metal
price to stock levels before stock gets
so far out of balance. Industry needs
better access to financial credit. Environmental standards should be more
equal between countries around the
globe.
Further consolidation in the secondary aluminium industry is the
only way to ensure its survival in
Europe and North America. The closures and idled capacity seen so far
are not enough to ensure the industry survives. Secondary aluminium
consumption fell by up to 40% in the
first half of 2009 compared with 2007
levels. But overcapacity continues to
restrict its recovery.
It is predicted that in ten years
there will be about ten secondary aluminium-producing companies in Europe. Moreover it is estimated there
would be only one major company
per country in Europe by 2019. There
will be various cycles of consolidation and, ultimately, a higher diversification in recycled production.
■
ALUMINIUM · 3/2010
S
AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e
A LPU e
M IcN II U
Interview mit Thomas Reuther,
Vorstandsmitglied der Trimet
Aluminium AG
„Wir bieten die
klassischen Stärken
des Mittelstandes:
kurze entscheidungswege, eine gesunde
Finanzstruktur, ein
marktnahes Management“
Die Trimet Aluminium AG in
Essen ist nicht nur der größte
Produzent von Hüttenmetall in
Deutschland, sondern betreibt
auch ein umfassendes Recycling,
das sowohl marktorientiert ist
als auch die Versorgung der ei­
genen Automotive­Gießereien in
Ostdeutschland sicherstellt. Die
Redaktion ALUMINIUM sprach
mit Thomas Reuther, verantwort­
licher Vorstand für die Bereiche
Recycling und Automotive, über
die allgemeine Marktsituation für
die Umschmelzbetriebe und über
das Recyclinggeschäft der Trimet
in Verbindung mit den eigenen
Gießereiaktivitäten.
Fotos: Trimet
Drehtrommelofen in Gelsenkirchen
Thomas Reuther
ALUMINIUM: Herr Reuther, die Krise
in der Automobilindustrie hat die Recyclingbetriebe im vergangenen Jahr
arg in Mitleidenschaft gezogen. Wie
schätzen Sie die aktuelle Lage ein?
Reuther: Der Markt der Umschmelzlegierungen ist derzeit durch eine
deutlich gestiegene Nachfrage insbe-
ALUMINIUM · 3/2010
sondere bei den Abnehmern aus der
Automobilindustrie gekennzeichnet.
Die Schrottpreise sind wegen des
strengen Winters stark nach oben
geschnellt und außerdem treten Indien und China wieder stärker am
Markt auf. Auf der Produktionsseite
sind eine Reihe von Kapazitäten in
Deutschland und Europa entweder
vorübergehend stillgelegt worden
oder ganz vom Markt verschwunden.
ALUMINIUM: Um welche Größenordnung handelt es sich dabei?
Reuther: Ich schätze, dass die Recyclingkapazität von rund 800.000
Tonnen in Deutschland um ein gutes
Viertel gesunken ist.
ALUMINIUM: Wird diese Entwicklung die Ertragssituation der Umschmelzer verbessern?
Reuther: An der Margensituation
hat sich bisher nichts geändert. Man
partizipiert nicht an höheren Legierungspreisen, hat aber höhere Finanzierungskosten beim Einkauf. Das ist
ein Problem, denn wenn die europäischen und deutschen Umschmelzer aufgrund ihrer wirtschaftlichen
Situation nicht in der Lage sind, die
Schrottpreise zu finanzieren, fließt
das Material schnell an Dritte.
ALUMINIUM: Sie sprechen damit die
viel zitierte Finanzierungsklemme
der Unternehmen an. Wie gravierend
ist denn das Problem?
Reuther: Die Finanzierung des Umlaufvermögens, sprich der Schrottund Fertigwarenbestände, ist für
viele mittelständische Unternehmen
deutlich schwieriger geworden, da
sie nicht über ausreichend Liquidität
bzw. Finanzierungslinien verfügen.
Dazu gibt es oftmals für diese Unternehmen keine ausreichende Kreditversicherung, was wiederum zu Aufschlägen bei den Schrottpreisen im
Einkauf führen kann. Hinzu kommt,
dass die Banken bei der Festlegung
von Konditionen heute vielfach
Branchen katalogisieren und weniger
in die Einzelbetrachtung von Unternehmen gehen. Als Umschmelzer für
die Automobilindustrie hat man es bei
den Banken eher schwer.
ALUMINIUM: Wie stellt sich die
Lage für Trimet dar, die ja nicht nur
Hüttenproduzent, sondern auch Umschmelzer und Autozulieferer ist?
Reuther: Unsere Situation unterscheidet sich grundlegend von der
des Wettbewerbs. Wir haben den
Handel, das Umschmelzen, die Hütten und in der Verarbeitung das Automotivegeschäft. Den größten Teil
unserer Schrotte beziehen wir von
unseren Kunden, zum Beispiel von
Druckgießereien und Weiterverarbeitern, bei denen große Mengen
Späne anfallen. Wir streben vor allem
langfristige Verträge mit den Kunden
an. Dem kommt entgegen, dass die
klassischen Verarbeiter den Schrott
als durchlaufenden Posten und kalkulierbare Größe behandeln wollen.
Da kann man auf LME-Basis dann mit
Abschlägen und Prämien die Schrotte
kaufen. Bei dem Großteil des Materials, das wir kaufen, handelt es ➝
33
ALUMINIUMrecycLINgINDUSTrIe
sich um sortenreine Neuschrotte. Der
kleinere Teil sind Altschrotte, die in
der Regel über den Handel bezogen
werden, dies ebenfalls im Rahmen vor
allem langfristiger Verträge.
ALUMINIUM: Kaufen Sie die Schrotte zielgerichtet mit Blick auf ihre Gießereien Harzgerode und Sömmerda
ein?
Reuther: Das Recyclinggeschäft bei
Trimet ist nicht primär auf das eigene Automotive-Geschäft in unseren
Gießereien ausgerichtet, sondern
marktorientiert. Der Vorteil bei Trimet ist, dass wir vom Handel bis zum
Recycling alles bedienen können.
Wir nehmen zum Beispiel von Automobilisten Sekundärschrotte zurück
und liefern im Gegenzug Primärlegierungen. Das ist nur eine Frage des
Tauschpreises. Für Schrott gibt es
immer einen Markt, die Aufgabe des
Händlers ist es, den jeweils passenden
Markt zu finden. Dabei konzentrieren
wir uns auf Deutschland und Europa.
Wir agieren hier kundennah, zumal
viele unserer Kunden diese Schrotte
brauchen, um ihre Produktion aufrechtzuerhalten.
ALUMINIUM: Das Recycling ist also
ein eigenständiges Standbein unabhängig vom Gießereigeschäft?
Reuther: Im Grunde sind wir hier
strukturiert wie jeder Großkonzern
– mit Geschäftsfeldern, die ergebnisverantwortlich sind. Natürlich hat die
Versorgung unserer Automotive- und
Formate-Gießereien hohe Priorität.
Am Hüttenstandort in Essen werden wir Ende des ersten Quartals
wieder alle Elektrolysen in Betrieb
genommen haben, das sind aufs Jahr
gerechnet 160.000 Tonnen Primärproduktion. Dem stehen 230.000
Tonnen Gießereikapazität gegenüber.
Das Delta von 70.000 Tonnen decken
wir über Kaltmetall, etwa zwei Drittel davon aus Schrotten, weil das so
hergestellte Metall kostengünstiger
ist. Aber wenn wir über Recycling bei
Trimet reden, sprechen wir über ein
Schrottvolumen zwischen 150.000
und 170.000 Tonnen, das wir in der
eigenen Gruppe recyceln. Darüber
hinaus handeln wir in der Größenordnung von 80.000 bis 100.000
Tonnen Aluminiumschrotten. Hier
ergänzen sich unsere Produktion und
unser Handelsgeschäft.
34
Kontrolle von Gussteilen in Harzgerode
ALUMINIUM: Die 170.000 Tonnen
werden in Essen, Gelsenkirchen und
Harzgerode eingeschmolzen?
Reuther: Wir haben an den Standorten in Gelsenkirchen und Harzgerode
gut 100.000 Tonnen Metallbedarf, die
eingeschmolzen werden, hinzu kommen jene Mengen Schrott, die in die
Hüttengießerei in Essen in den Prozess fließen. Wir produzieren schon
heute rund ein Drittel des Metalls in
Essen aus Schrotten. Ein standortnahes Recycling hat für uns eine hohe
Bedeutung. Gerade mit Blick auf das
Automotivegeschäft.
ALUMINIUM: Können Sie das näher
erläutern?
Reuther: Denken Sie an die CO2-Diskussion, die für Hüttenbetriebe wie
für die Automobilhersteller virulent
ist. Mit einem standortbezogenen Recycling können wir unsere Energiebilanz auf sehr wirtschaftliche Weise verbessern. Das angesprochene
Delta von 70.000 Tonnen Kaltmetall,
um unsere Hüttengießerei in Essen
auszulasten, können wir mit einem
Bruchteil der Energie einschmelzen,
die ein normales Umschmelzwerk
benötigt. Das Metall aus der Elektrolyse geht mit über 900 Grad Celsius
in die Gießerei. So heißes Material ist
nicht vergießbar, und der Schmelzpunkt von Aluminium liegt bei 660
Grad Celsius. Wir geben die Schrotte
daher als Kühlmetall zum flüssigen
Primäraluminium hinzu. Wir setzen
dabei sortenreine, blanke Produktionsschrotte wie Fensterprofile ein
und mit zunehmendem Anteil auch
Fahrwerksteile, weil diese Produkte
vor allem aus Primärmetall hergestellt
werden.
ALUMINIUM: Erfolgt der Einsatz von
Primär- statt Sekundärlegierungen
für diese Produkte aus Qualitätsgründen?
Reuther: Das ist vor allem eine Frage der Legierungsentwicklung, die in
der Vergangenheit nur von wenigen
Umschmelzwerken vorangetrieben
wurde. Für Sicherheitsteile im Automobil werden vorwiegend Hüttenlegierungen eingesetzt, weil es oftmals
keine vergleichbaren Umschmelzlegierungen gibt. Unsere F&E arbeitet
daran, Umschmelzlegierungen zu
entwickeln, die die identischen Sicherheitsanforderungen erfüllen und
dabei gleichzeitig Kostenvorteile mit
sich bringen. Unser Ziel ist es, uns
über die F&E-Expertise als Entwicklungspartner zu positionieren. Wir
haben alle Prüfmöglichkeiten und
mit Essen und Harzgerode zwei hervorragend ausgebaute F&E-Standorte
inklusive einer Versuchsgießerei in
Essen. Und wir haben grundsätzlich
auch die finanziellen Mittel, um uns
an Entwicklungsprojekten zu beteiligen. Wir bekommen so auch einen
Ansatz, unser Metall in Projekte liefern zu können, wenn sie serienreif
werden.
ALUMINIUM: Wie erfolgreich sind
Sie bei der Entwicklung von Umschmelzlegierungen als Substitut für
Primärmetall?
Reuther: Für einen OEM, der in der
Formel 1 aktiv ist, produzieren wir,
wenngleich nur in sehr kleinen Mengen, eine hoch anspruchsvolle ➝
ALUMINIUM · 3/2010
8. Weltmesse & Kongress
14. – 16. September 2010, Messe Essen
ALUMINIUM 2010
between innovation and environment
Aluminium als Werkstoff ist stabil, korrosionsbeständig
und leicht, lässt sich präzise verarbeiten, ist leitfähig und
steht für hohe Ästhetik. Die hervorragenden Eigenschaften
von Aluminium ermöglichen innovative Weiterentwicklung
und visionäre Produktgestaltung – und helfen uns, die
Umwelt zu schonen.
Erleben Sie auf der ALUMINIUM 2010 die vielfältigen
Anwendungsmöglichkeiten des Zukunftswerkstoffes
Aluminium und seine Alleinstellung im Spannungsfeld
zwischen Innovation und Umwelt.
Wir sehen uns in Essen!
Organiser:
Institutional Patron:
Partner:
Official International Media Partner:
International Media Sponsor:
www.efp.de
www.aluminium-messe.com
ALUMINIUMrecycLINgINDUSTrIe
Sonderlegierung, mit Eisenwerten im
normalen Primärbereich. Wir produzieren sie mit einer Umschmelzlegierung, die deutlich teurer ist, wenn man
sie als Hüttenlegierung herstellt. Der
Kunde hat uns bestätigt, dass unsere
Umschmelzlegierung aufgrund der
weiteren in ihr enthaltenen Komponenten sogar bessere Eigenschaften
aufweist als das Primärmetall, das er
vorher bezogen hat. Ein anderes Beispiel betrifft die Anfrage eines OEMs,
der eine Aluminiumlegierung mit
besseren dämpfende Eigenschaften
wünscht. Bisher wurde die Legierung
in Magnesium hergestellt. Wir arbeiten hier an einer Umschmelzlegierung
aus Aluminium. Eine solche Entwicklung kann heute kaum ein Umschmelzer in Europa vorantreiben. Entweder
drei klassische Konverter als reine
Warmhalte- und Legierungsöfen. Und
natürlich steht eine aufwendige Ablufttechnik dahinter, um die Grenzwerte der TA Luft einzuhalten. Harzgerode ist ähnlich aufgebaut: mit zwei
Trommelöfen in ähnlicher Größe wie
in Gelsenkirchen, vier Konvertern
und zusätzlich zwei Herdschachtöfen, weil wir aus der Produktion
der Gusslegierungen große Mengen
Kreislaufschrott zurückbekommen.
Das ist Schrott, der beim Stanzen der
Angüsse anfällt. Diese Herdschachtöfen können mit geringem Energieaufwand und Metallverlust diese eindeutig identifizierbaren Schrotte sofort
wieder einschmelzen und das Metall
für die Gussproduktion am Standort
einsetzen.
F&E-Versuchsanlage in Essen
fehlt die F&E-Expertise oder der Link
zur technischen Ebene der Automobilisten. Die Umschmelzer sind sehr
kostengetrieben und haben in diesem
Bereich in der Vergangenheit wenig
oder gar nicht investiert.
ALUMINIUM: Mit welcher Ofentechnik arbeiten Sie an den Recyclingstandorten?
Reuther: Die beiden Umschmelzwerke in Harzgerode und Gelsenkirchen betreiben wir mit herkömmlichen Drehtrommelöfen unter Salz.
Die genutzte Schmelzkapazität in
Gelsenkirchen beträgt rund 50.000
Tonnen. Wir produzieren dort mit
zwei Trommelöfen und vier Konvertern zum Auflegieren. Wir haben
einen 30-Tonnen-Herdschmelzofen,
um Festmetall zu schmelzen und
36
ALUMINIUM: Welche Produkte liefern Sie?
Reuther: Für uns ist wichtig, eine
breite Produktpalette anzubieten,
das heißt Flüssigaluminium, Vorlegierungen, Desox-Aluminium für die
Stahlindustrie und klassische Gusslegierungen, und dies nicht nur für die
eigene Produktion, sondern für den
Markt. Gelsenkirchen produziert fast
ausschließlich für Dritte im Markt,
Harzgerode – mit abnehmender Tendenz – zu 40 bis 50 Prozent für Dritte.
Wobei Harzgerode in der Produktion
deutlich wächst und dadurch mehr
Aluminium im eigenen Kreislauf
bleibt. Drei Viertel der Umschmelzproduktion, ohne den Standort Essen,
geht an Externe.
ALUMINIUM: Welchen Stellenwert
hat die Lieferung von Flüssigaluminium?
Reuther: In Gelsenkirchen wird ein
Kunde mit Flüssigaluminium beliefert. Wir wollen uns aber nicht zu
abhängig von der Just-in-time-Belieferung mit Flüssigmetall machen.
Außerdem wird unsere Gießerei in
Harzgerode mit Flüssigaluminium
versorgt. Das Schmelzwerk dort ergänzt sich gut mit der Gießerei. Wir
setzen in Harzgerode rund 50.000
Tonnen Schrotte ein, die Produktion
daraus geht zur Hälfte in die eigene
Gießerei, die andere Hälfte wird für
Dritte abgemasselt.
ALUMINIUM: Stehen derzeit neue
Investitionen im Recycling- oder Automotivegeschäft an?
Reuther: Große Investitionen sind aktuell nicht geplant. Wir haben in Sömmerda interessante neue Aufträge im
Bereich Mechatronic akquiriert. Dort
haben wir in eine neue Druckgussmaschine investiert und ein neues
Bearbeitungszentrum sowie ein neues
Schmelzaggregat aufgestellt. An allen
anderen Standorten arbeiten wir
derzeit nach dem Motto „Cash is
King“, geben nur dort Geld aus, wo
der Markt einen schnellen Rückfluss
bietet oder wo Ersatzinvestitionen
notwendig sind. Wir haben in Harzgerode im Rahmen des Jointventures
mit BMW die Kokillenproduktion gestartet. Hier kann es zu einem Kapazitätsausbau kommen, wenn sich weitere interessante Aufträgen ergeben.
Grundsätzlich bin ich ein Befürworter
„atmender Kapazitäten“. Unser Credo
ist es, in Partnerschaften zu wachsen.
Es macht keinen Sinn, in einer Industrie, die sehr investitionslastig ist und
das Payback sehr spät erfolgt, immer
wieder neue Kapazitäten aufzubauen,
wenn die vorhandenen Kapazitäten
im Markt ausreichen. So lassen wir im
Einzelfall in Abstimmung mit unseren
Kunden durchaus Produkte bei Dritten gießen. Die großen OEMs wollen
vor allem einen Systemlieferanten,
einen Ansprechpartner haben. Wenn
man den Weg der Partnerschaften
und Kooperationen geht, spart man
Investitionen und kann mit den vorhandenen Kapazitäten atmen.
ALUMINIUM: Können Sie auch dies
beispielhaft konkretisieren?
Reuther: Wir produzieren zum Bei-
ALUMINIUM · 3/2010
S
AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e
A LPU e
M IcN II U
Ko
AK T
NT
tiv planendes Unternehmen sind, mit
dem man auch über neue Produkte
sprechen kann, die vielleicht erst
2012 oder noch später starten. Und
wo der Kunde sicher sein kann, dass
sein Zulieferer Trimet Start-of-production und auch End-of-production
erleben wird. Wir bieten die klassischen Stärken des Mittelstandes:
kurze, schnelle Entscheidungswege,
eine gesunde Finanzstruktur, ein
marktnahes Management. Das hat in
der Vergangenheit zu Neuaufträgen
geführt und wird, da bin ich sicher,
auch in Zukunft so sein.
■
UN T
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NE
H
Wä
AUToMoT
iv
RMETAUscHER
EN
E
BA
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i NdU
sTR
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ALUMINIUM · 3/2010
eher gestärkt als geschwächt aus
der Krise hervorgehen. Das hat sich
letztes Jahr gezeigt und sich Anfang
dieses Jahres bestätigt.
ALUMINIUM: Gestärkt aus der Krise
– heißt das, auf die Schwäche der anderen setzen und auf eine Marktbereinigung hoffen?
Reuther: So simpel möchte ich es
nicht verstanden wissen. Aber gerade
in Krisenzeiten zeigt sich im Markt,
wo die Kompetenz und Stärke eines
Unternehmens liegt. Der eine oder
andere potenzielle Kunde erkennt
und honoriert, dass wir ein konserva-
M
spiel ein Getriebegehäuse, das relativ
hohe Zuwachsraten aufweist. Wir gießen das Produkt heute mit einer Maschine und es besteht die Aussicht,
größere Mengen zu liefern, die wir
mit dieser einen Maschine aber nicht
bereitstellen können. Sollen wir nun
zwei, drei Millionen in die Hand nehmen und eine weitere Maschine aufbauen, obwohl wir von anderen Unternehmen, zu denen wir ein partnerschaftliches Verhältnis unterhalten,
wissen, dass sie über eine passende
Anlage verfügen. Wir besprechen
mit dem OEM dann, ob eine solche
Partnerschaft akzeptiert
wird, bei der wir Systemlieferant bleiben und für
die Produktqualität haften. Das wird ganz transparent kommuniziert, ist
ein durchlaufender Posten für uns, und allen ist
geholfen. Der Kunde ist
versorgt und hat auf diese
Weise sogar ein Mehr an
Ausfallsicherheit. Solche
Kooperationen waren früher nicht vorstellbar, das
ist von uns vorangetrieben
worden.
ALUMINIUM: Kommen
wir nochmal zurück auf
die Geschäftslage im Recyclingbereich der Trimet. Wie würden Sie die
aktuelle Situation für Ihr
Unternehmen charakterisieren?
Reuther: Das reine Mengengeschäft
entwickelt
sich bei uns sehr gut, die
Margen sind zufriedenstellend. Schrotte sind knapp
verfügbar, das spiegelt
sich auch im Preis wider,
aber wir klagen auf einem
akzeptablen Niveau. Auslastungsprobleme
wie
Anfang 2009, wo wir viel
Metall der Börse angedient hatten, um nicht in
Kurzarbeit gehen zu müssen, haben wir derzeit
nicht. Trimet steht meiner
Einschätzung nach besser
da als viele Wettbewerber.
Unsere Probleme sind beherrschbar. Wir werden
F. W. Brökelmann Aluminiumwerk GmbH + co. KG
oesterweg 14 | 59469 Ense-Höingen
Telefon: +49 (2938) 808-0 | www.broekelmann.com
T. T. Tomorrow Technology
ALUMINIUM recycLINg INDUSTry
Some of T. T.’s vehicles for the recycling industry: two scrap transporters, a coil transporter and the Multifunctional Furnace Tending Vehicles
T. T. Tomorrow Technology celebrates its 10th anniversary
Spring of the year 2000 was the
first time that T. T. Tomorrow Tech­
nology exhibited in public. This
was at Metef when the new com­
pany, based nearby Padua in Italy,
was launched to design and manu­
facture vehicles and equipment
for the metals industry. T. T. came
into being, with its official start in
February of that year.
“We wanted to give aluminium
processing technology a shot”, recalls
managing director Giovanni Campice.
At that early stage it was not to be expected that the new venture would
play such an important role in defining
contemporary casthouses, recycling
furnace management, anode cutting
and slotting in smelters. From the very
beginning, T. T. has always looked to
the future, asking “What can be done
better?” The answer has usually been
a better way or new approach to metal
processing technology.
The new company soon led the
industry in the development of many
significant innovations, including the
Multipurpose Furnace Tending Vehicles, which have changed the way furnaces are charged and cleaned, and
the dedicated charging or de-drossing
and furnace cleaning machines.
In September 2001, T. T. launched
the world’s first anode cutting machine. A few years later the powerful
combination of anode handling technology with cutting know-how proved
to be the foundation for the success
of the anode slotting equipment.
To chronicle all the events of the
past ten years would take too long:
T. T. has achieved many goals and
38
successfully entered many fields of
competition, while innovations and
moments of inspiration have made
the company what it is today. Development has not only focused on
markets and products, but also on
expanding the company’s offices and
workshops to meet the standards of
an international first class company.
Reliability, high profitability, ease
of use and safety are recognised by
customers as the main qualities characterising the products supplied by
the Italian company. The most recent
and important projects that T. T. completed include:
• A by-pass anode handling line and
an anode slotting line, supplied to
Voerde Aluminium (formerly Corus
Aluminium) in Germany
• A Multifunctional Furnace Tending Vehicle to charge, de-dross and
clean melting furnaces; and a rotating deck vehicle with 9.5 meters boom
reach to de-dross and clean furnaces
at Amag Casting in Austria; two similar vehicles were also supplied to the
neighbouring company HAI Hammerer Aluminium Industries for their
two plants in Ranshofen (Austria) and
in Santana (Romania)
• An automatic, rail-mounted furnace charging machine with rotating
deck, mobile charging box with fully
closed hood (to eliminate exhaust
and smoke emission); and two fully
automatic rail-mounted de-drossing
machines were supplied for the new
expansion of Eural Gnutti casthouse
in Brescia (Italy). Identical machines
were also supplied to the new Alumil
billet plant in Kilkis (Greece)
• A fully automatic, rail-mounted
ingot charging machine which works
in combination with the ‘sister’ fully
automatic de-drossing machine manufactured by T. T. have been in nonstop operation since August 2009 at
the Fagor Plant in Spain.
The reference list also includes
the ‘jewels’ of the T. T. product range,
notably the Multifunctional Furnace
Tending Vehicles which have been
manufactured for Germany, France,
Norway, Turkey, The Netherlands,
Luxembourg, and of course for Italy.
Further main products in the T. T.
range are:
• Automatic charging machines for
aluminium furnaces
• Automatic, manual and radiocontrolled systems for de-drossing
and cleaning aluminium furnaces
• Liquid metal tapping and
transport vehicles
• Special vehicles for internal
handling of aluminium coils and
rolling mill rolls weighing up to
50 tonnes;
• Aluminium scrap transport
vehicles with a tilting charging
box of 63 m3 capacity
• Dross presses for aluminium dross
treatment
• Anode handling, cleaning, cutting
and palletising lines;
During 2010 T. T. Tomorrow Technology will be exhibiting on various
occasions, starting in Italy at Metef
(Montichiari-Brescia) in April. T. T. is
also an exhibitor at the ALUMINIUM
fair in Essen, Germany, in September.
Both events will provide good opportunities to discuss the company’s new
products and to exchange ideas and
opinions with the visitors.
■
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remelting and refining modes in advanced
recycling of wrought aluminium alloys, Part I
In recent decades an increasingly
large fraction of the world’s supply
of wrought aluminium alloys has
come from the aluminium scrap
recovered from industrial waste
and discarded consumer items.
The reason for that is the creation
of an additional net increase in
added value during the produc­
tion of wrought alloys achieved
through the consumption of in­
expensive raw materials. In other
words, the common way of creat­
ing new added value inside the
casting house is in substituting as
far as possible costly and energy­
intensive primary aluminium and
the alloying elements by cheaper
and commonly available sources
of aluminium alloys – preferably
lower grades of scrap.
However, replacement (of even a
minor part) of primary aluminium
in wrought alloys with the recycled
counterpart originating from lower
grades of scrap (typically scrap contaminated with various non-metallic
impurities) – without at the same time
influencing the quality of the alloy – is
very demanding from the metallurgical point of view [1-7]. Developing a
more complete understanding of the
compositional tolerances in wrought
aluminium alloys is still under investigation of many academic and industrial projects [8-10].
Recycled aluminium is produced
by remelters and refiners. Refiners
produce cast alloys and aluminium
for deoxidation of liquid steel, while
remelters produce wrought alloys.
Casting alloys have a concentration of
alloying elements of up to 20% while
wrought alloys of up to 10%. Initially,
remelters were distinguished from
refiners by a lack of refining capability, but nowadays many remelters also
practice refining and filtering of their
recycled metal in order to make it
competitive with primary metal, even
for very demanding applications.
As the demand for clean scrap from
ALUMINIUM · 3/2010
other recyclers increases its price,
remelters increasingly start consuming lower grade scrap to meet their
needs. Because the use of lower grade
scrap makes quality control more demanding, refining and purification are
becoming steps regularly practised by
producers of wrought alloys [11].
Remelters must select the appropriate quantity and quality of scrap to
suit the chemical composition of the
wrought alloy to be produced. Hence,
extra care must be taken to keep the
different aluminium alloys separate.
In practice, there are two different approaches for achieving the required
chemical composition of wrought alloys made from recycled aluminium:
• before melting, by combining the
appropriate qualities and quantities
of scrap, primary aluminium and the
alloying elements
• during melting, by diluting the impurity content with primary aluminium to the needed level and, at the
same time, adding the amount of alloying elements necessary to achieve
their standard concentration in the
diluted melt.
Evidently, technique of achieving
of the proper chemical composition of
wrought alloys before melting is more
profitable, but also much more demanding from the viewpoint of scrap
pre-screening, optimal pre-sorting
and separation. For typical production (melting performed in real time)
this procedure is also less flexible regarding the chemical composition of
the available scrap, sorting and scrap
allocation due to the overall requirement for minimal consumption of primary metal and alloying elements. It is
important to note that the new added
value created by this procedure depends strictly on the successful replacement of primary aluminium and
alloying elements by a cheaper input
composed of different alloy blend obtained by careful selection and mixing
of various scrap materials. The decisions regarding what scrap material to
use, which and how much to sort and,
V. Kevorkijan
V. Kevorkijan, Maribor
Varužan Kevorkijan, independent researcher, located in Maribor, Slovenia
finally, allocating the compositions
which are to be produced are crucial
for achieving sufficient flexibility and
economic benefits.
On the other hand, it is important
to note that adjustment of the proper
chemical composition of wrought alloys during melting (better known as
‘sweetening’ of the melt with primary
aluminium) is a common production
practice by most traditional remelters around the world. For refiners
it is common practice to mix different alloys with alloy-specific scrap
batches before loading the scrap into
the furnace.
Because wrought alloy scrap cannot be used to produce new wrought
alloy unless one or more of the impurities are diluted by the addition of
primary metal, it is difficult to expect
that the refining mode for production
of wrought alloys will prevail until
the development of technology for
segregating scrap by alloy type; the
commercial use of this technology is
currently in its infancy.
Thus, a significant breakthrough
in the future would be necessary for
completing the initial evolution of
existing remelters of wrought alloys
into refiners, willing to separate raw
material of uncertain chemistry into
well defined batches, and blend appropriate proportions of them ➝
39
ALUMINIUM
ALUMINIUM recycLINg INDUSTry
Clean high-grade scrap of wrought aluminium alloys
to produce a consistent wrought alloy with the required chemistry at the
lowest possible cost.
The benefits of production
of wrought aluminium
alloys from low grade scrap
In recent years recycling of low grade
scrap has become an increasingly important issue of metal supply for both
casting and wrought alloys. Looking
to the future, production of recycled
aluminium of standard quality from
the cheapest sources will play an
increasingly significant role in the
growth of the European aluminium
industry. Despite the economic slowdown, the consumption of primary
aluminium in the EU is expected to
increase to eight million tonnes by
2012, while European production of
primary aluminium is expected to decrease gradually down to 2.86 million
tonnes by 2012. The gap between the
expected production of primary aluminium and its consumption of about
5.24 million tonnes will be covered by
imports and recycling inside the EU.
At the same time, the continuous
increase in the relative proportion of
recycled versus primary aluminium
sources will be driven by the pressure
to improve business results and striving for individual profit maximisation.
Additional, very important benefits of
recycling aluminium from low grades
scrap are:
• spreading the risk of a potential
shortage of raw materials by diversifying the supply sources of aluminium
40
away from exclusively primary metal
and clean scrap suppliers
• an improvement in logistics – ensuring an appropriate and cost effective supply from different scrap
sources. Others advantages of recycling low grades of aluminium scrap
are the additional energy savings
and higher compositional flexibility
in combination with clean grades of
scrap and dross.
For several decades, a kind of belief existed in the aluminium industry
that the standard quality of wrought
alloys could be achieved only by
combining a sufficient amount of primary aluminium, internal scrap and
only clean, well sorted external scrap.
Consequently, ingots made from primary aluminium, internal scrap and
clean industrial or external old scrap
(single wrought alloy with less than 2
wt.% of non-metallic impurities) were
obligatory in the mass production of
wrought alloys as the only source of
the new and recycled aluminium capable of assuring the standard quality
of end products.
Scrap for the production of wrought
alloys should be sorted with strict
control of the concentration of alloying elements in order to achieve the
prescribed compositional tolerances
[12]. An additional problem is caused
by the very limited ability of wrought
alloys to tolerate elements not normally present in their composition.
In other words, well defined wrought
scrap of the proper composition could
be effectively remelted into a wrought
alloy of the same composition, but it
is very demanding to achieve a new
wrought composition by direct reuse,
without addition of primary metal
and alloying elements. The addition
of primary aluminium is necessary
to dilute impurities (elements not
normally present in wrought alloy)
to an acceptable level, while alloying elements are added, if necessary,
for correction of their concentration.
Thus, most external scrap inside the
EU (above 60%) is preferably applied
for the production of casting alloys
and only the remainder is dedicated
to remelting.
Although non-metallic impurities
can also significantly influence the
quality of the molten metal, it is not
obligatory that scrap for wrought alloys should be clean, without organic
and other non-metallic impurities, if
these could be effectively removed
before or during the recycling procedure. Some of the advanced melting
furnaces, such as various rotary or
multi-chamber units, enable the direct melting of highly contaminated
scrap (e. g. painted and lacquered)
with thermal de-coating and recycling
occurring consecutively.
Moreover, in internal technical
documentation for the production of
wrought alloys, more or less empirical
compositions were often established,
resulting in production mixtures with
the prescribed amount of primary aluminium, internal, industrial external
and old external scrap. However, it is
important to note that such empirical
compositions are usually adapted to
the common availability of various
raw materials and in many cases are
below the real potential of possible re­
placement of primary aluminium by
scrap without influencing the standard quality of the final products. The
problem is that in many cases these
empirical compositions are also approved by the customers, becoming
in that way a contractual obligation
of the producer of alloys.
On the other hand, it is well known
that for aluminium alloys (especially
wrought alloys) a practical ‘compositional tolerance limit’ exists and a
fairly complete knowledge of these
tolerance limits for all elements is
needed, especially in recycling operations where unexpected and unusual
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impurities can creep in inadvertently, and even normal impurities may
tend to accumulate and build up to a
disastrous degree. In most cases, the
influence of these tolerance limits for
various elements and various combinations of elements on the properties
(and particularly on selected properties) of wrought alloys is not well
investigated. Because of that, customers often require more narrow com­
positional tolerances than are necessary, creating unnecessary losses for
themselves and the casting house.
Customers lose an important part of
the competitiveness of their products
in downstream business activities by
paying more for non-optimal tolerance limits and, at the same time, the
casting house loses the added value
by producing alloys from more expensive inputs.
As an example, the average new
added value created by producing
wrought alloys from external contaminated scrap is about 7% of LME.
For aluminium dross in the form of
pressed skulls the new added value is
significantly higher and could reach
approximately one third of LME
(considering pressed skulls as internal scrap).
Difficulties in recycling existing
wrought aluminium alloys
As already mentioned the main difficulty in production of wrought aluminium alloys from scrap is to achieve
the proper chemical composition of
the melt with minimal addition of
primary aluminium and alloying elements. Technically, the problem is in
the missing technology (an economically acceptable chemically based
refining process) for reducing the
concentration of critical alloying elements such as copper, iron, manganese, silicon and zinc, in a melt batch
produced from various sorts of scrap.
Once the concentration of these critical elements in the melt is above the
concentration limit for a particular
wrought alloy, the only practical solution would be their dilution by primary metal.
Another technical solution is to
avoid incorrect melt composition by
carefully predicting and assuring the
ALUMINIUM · 3/2010
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chemical composition of the batch in
a pre-melting stage of casting. In principle, there is also a third solution:
convince the customers to accept the
so-called ‘recycling friendly wrought
alloys’ – in other words, alloys with
broad compositional tolerance limits
and, consequently, to some extent of
different quality to cost ratio. This
could be an important future trend in
developing new wrought alloys, working hand in hand with customers in
implementation of their requirements
to scrap-friendly compositions [1-4],
but for the existing alloys and existing
customer demands such an approach
has definitely a quite limited potential
and is also too risky.
In most of today’s plants, the predominant mode of recycling – more
accurate scrap blending or very strict
melt dilution is decided by the margin
between recycled metal and primary
aluminium. However, it is important
to note that this margin – the difference in price of primary aluminium
(which is determined globally) and
the recycled metal (which is calculated locally) – is affected by internal and
external circumstances. Among internal factors the most important are:
• permanent and stable sources of
new and old scrap, concentrated sufficiently in one area to justify the cost
of collecting
• a scrap collecting and sorting infrastructure including devices for removing impurities and delivery to a
recycling plan
• a method of recycling that is economically competitive with production of primary aluminium
• a market willing to accept the composition and the quality of wrought
alloys made from scrap.
More expensive, clean and sorted
scrap (mainly new or industrial scrap)
contains a minimal concentration of
critical elements, while in old scrap
of lower cost it becomes more critical.
In typical municipal old scrap, which
is a cost-effective source of aluminium, the minimal concentration of
critical elements (silicon, iron, copper, manganese, zinc, magnesium) is
typically too high for direct remelting
into wrought compositions without
dilution by primary aluminium, see
Table 1.
On the other hand, in new scrap resulting from the collection and/or
treatment of the metal that arises
during the production of aluminium
products before these are sold to the
final users, the right alloy composition is assured in advance; however,
the cost of such scrap is significantly
higher and its availability is usually
limited to closed production loops.
Element
Fe
Si
Cu
Mn
Zn
Mg
Cr
Ni
Pb
Sn
Bi
Ti
Concentration (%)
0.60-1.00
0.30-9.00
0.25-4.00
0.60-1.50
0.25-3.00
2.00
0.05-0.30
0.04-0.30
0.02-0.25
0.02-0.30
0.02-0.30
0.05-0.25
Table 1: Typical concentrations of the main
alloying elements in old municipal old
scrap [13]
The economics of contaminated
wrought scrap recycling
The economics of wrought aluminium
alloys recycling from scrap is specific
and differs from the economics of
cast alloys recycling since cast alloys
have higher compositional tolerance
limits for impurities and can absorb
a wider variety of scrap. During the
production of cast alloys from scrap
of various compositions, refiners are
able to add alloying elements and
remove certain unwanted elements
after the melting process. Cast alloys
tend to have higher alloy content than
wrought alloys and because of that are
difficult to recycle into anything other
than cast alloys, since the removal of
most alloying elements from molten
aluminium would be impractical. On
the other hand, wrought scrap cannot
be used to produce new wrought alloys unless separated by alloys or alloy groups and/or diluted by the addition of primary metal.
In this regard, a possible way of
improving the recycling of wrought
aluminium alloys is the use of new
and old scrap with higher amounts of
organic impurities. Most aluminium
scrap mixtures currently used ➝
41
ALUMINIUM recycLINg INDUSTry
for the production of wrought aluminium alloys from low grade scrap
have an organic impurities content
lower than 8 wt.%. The most common
organic impurities are oils, polymers
such as polyester and epoxy, rubber,
lacquers, paints, etc. In some heavily
contaminated aluminium scrap, the
organic impurity level exceeds 18 to
20 wt.%, while in clean industrial scrap
the non-aluminium impurity level is
usually less than 2 wt.%. The main
reasons to start using contaminated
instead of clean scrap for production of wrought aluminium alloys are
in improved added value (net profit
surplus achieved per weight unit of
aluminium or aluminium alloys of
standard quality recycled from low
quality aluminium scrap) and better
logistics (scrap sourcing, availability
on the market and improved flexibility in supplying). The key advantage
is in the fact that the cost of contaminated scrap is significantly lower than
the cost of clean scrap of the same
pre-sorting quality (e. g. single alloy
or single series grade), in that way
providing an opportunity for producing aluminium wrought alloys of the
standard quality and with improved
competitiveness. The prerequisite for
that lies in appropriate performance
of the entire recycling process, from
the scrap sourcing and purchasing
strategy to the complete recovery of
all by-products, in order to achieve
the standard quality of recycled aluminium and the proper economy. In
practice, irrespective of the fact that
the recycling of contaminated scrap
is more demanding and costly than
remelting of clean scrap, the total cost
per weight unit of recycled aluminium
or aluminium alloy of standard quality produced from contaminated scrap
is lower than the cost of the remelted
aluminium or aluminium alloy counterpart produced from clean scrap
which is nowadays much in demand
for the production of wrought alloys.
As a rule, clean scrap (e. g. scrap
with a minimum of 98% of Al) represents a costly raw material for the
production of wrought alloys. Its
market price is close to the theoretically expected, calculated according
to the aluminium content and cost
of recovery. Therefore, the usage of
42
clean scrap in production of wrought
alloys provides only limited possibilities for creating new added value or,
in another words, for lowering of the
cost of the impute. Typically, the market prices of clean scrap of a single
wrought alloy vary slightly below or
above the price of the counterpart
ingots, depending on their market
availability.
On the contrary, the market price
of contaminated scrap (scrap with
e. g. 80% of Al and 20% non-metallic,
mostly organic impurities) ranges significantly (10-25%) below the theoretically expected based on the aluminium content and cost of recovery.
Thus, taking into account the cost
of recycling and all related costs, the
total cost of production of recycled
aluminium alloy fabricated from
clean scrap would usually be near the
cost of melting the same alloy from
primary aluminium (including the
cost of the appropriate alloying elements). In contrast to that, by using
less clean scrap (scrap contaminated
with organic impurities) and applying
the proper recycling technology, some
higher net added value (typically between 5 and 10%) can be achieved.
It is important to note that the significant part of the new added value
is gained by the successful buying of
less clean grades of scrap. Hence, it is
necessary to understand the local new
and old scrap market and organise
cost-effective buying from the nearest
scrap suppliers or though collecting
new scrap.
The second part of the new added
value is achieved in the process of
scrap separation, where an optimal
level and method (e. g. hand sorting
or automatic screening) of separation
should be selected following the compromise between the degree of compositional separation and the cost of
achieving it, also taking into consideration that a lower level of compositional separation leads during final
melting to the higher consumption of
primary aluminium for diluting impurities. Of all the sorting technologies,
hand sorting remains the most common method of recovering aluminium. Because a load of mixed scrap
(even new, industrial) often includes a
limited number of alloys, hand sorting
often makes it possible to produce single alloy scrap products. Even if this
is not possible, hand sorting can help
meet specifications for other scrap
grades by removing impurities. Often,
a dealer’s experience and knowledge
of his suppliers is useful in hand sorting, because the appearance of a piece
of new scrap – the shape of a punching, the type of scrapped part – will be
sufficient to identify the alloy.
Finally, the remaining part of the
new added value depends on the competitiveness of the selected remelting
technology, which should be able
to provide the highest metal yield, a
standard quality of the molten metal
and operating in accordance with
standard environmental regulations.
references
1. D. G. Altenpohl, P. Paschen, ALUMINIUM, 77 (1/2) (2001) p. 8.
2. S. K. Das, Materials Science Forum,
Vols. 519-512 (2006) p. 1239.
3. S. K. Das, In: Light Metals 2006, Ed. T. J.
Galloway, TMS-AIME, Warrendale, PA
(2006) p. 911.
4. S. K. Das, Aluminium Recycling and
Processing for Energy Conservation and
Sustainability, Ed. J. A. S. Green, ASM International (2007) p. 147.
5. R. Hirve, Metalworld, Vol. 8, No. 3
(2009) p. 32.
6. R. E. Sanders, Jr., JOM, 53(2) (2001),
p.21.
7. J. B. Hess, Metal. Mater. Trans. A, 14(2)
(1993) p. 323.
8. D. G. Altenpohl, Aluminium: Technology, Applications, and Environment, 6th
ed., TMS-AIME, Warrendale, PA (1998) p.
15.
9. G. Rombach, In: Light Materials 2002,
Ed. W. Schneider, TMS-AIME, Warrendale, PA (2002) p. 1011.
10. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway,
NW (2007) p. 9.
11. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway,
NW (2007) p. 171.
12. Aluminium Association, International
Ally Designation and Chemical Composition Limits for Wrought Aluminium and
Wrought Aluminium Alloys, Aluminium
Association, Arlington, VA (2009).
13. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway,
NW (2007) p. 101.
To be continued
in ALUMINIUM 4/2010
ALUMINIUM · 3/2010
Technology
Hochbetrieb in der Werkstatt von Danieli Fröhling
ALUMINIUM
Das Krisenjahr 2009 gut gemeistert
In der Montagewerkstatt von Danieli Fröhling in Meinerzhagen herrscht derzeit Hochbetrieb
Inside the Danieli Fröhling assembly shop in Meinerzhagen, now working busily
A busy time in the Danieli Fröhling workshop
The crisis year 2009 overcome well
Whereas 2009 was one of the
most difficult business years ever
for machinery and plant engineering, with drastic order cut-backs, a
few such equipment manufacturers are beginning to see signs of a
modest market recovery. A lot of
work is now going on in the workshop of the rolling plant manufacturer Danieli Fröhling in Meinerzhagen, Germany, to assemble
various machines and plant components to the required quality
in time for a series of scheduled
delivery dates. This relates mainly
to three major contracts: a coldrolling plant for the steel industry,
but also two trimming and slitting
units for the aluminium industry.
During a visit to the workshop of
Danieli Fröhling in Meinerzhagen,
managing director Jörg Schröder
seemed reasonably satisfied with the
present order status of his company:
“The market is again showing some
signs of life after last year, which was
marked by many project postponements. Since then, projects shelved
in the copper and aluminium branches have been revived again.” On the
other hand, there is still silence, as it
ALUMINIUM · 3/2010
were, from the stainless steel sector
because of substantial overcapacities
in the market.
The impetus for new equipment
still comes mainly from China in both
the copper and aluminium sectors.
South America is also promising. In
the past year Danieli received an order from Termomecanica São Paulo,
market leader for the production of
long and flat copper and copper-alloy products in the South American
market, for the construction of a prerolling mill and a finish-rolling mill
for strip widths up to 600 mm, and
for a milling machine. The Russian
market, however, has not so far lived
up to expectations, right across the
sector; there, hardly any projects are
currently in progress. The market in
Europe and Germany is characterised
by modernisations of existing plants
more than anything else.
Danieli Fröhling managed to cope
with last year in a more balanced
way than many of its competitors.
Since its order books were well filled,
the company was able to keep going
throughout the year without having
recourse to short-time work. In fact,
over the past 18 months the company
has even taken on 15 new and ➝
Während 2009 eines der schwierigsten Geschäftsjahre für den
Maschinen- und Anlagenbau mit
drastischen Auftragsrückgängen
war, spürt der eine oder andere
Anlagenbauer wieder eine leichte Belebung des Marktes. Beim
Walzwerkbauer Danieli Fröhling
gibt es derzeit eine Menge Arbeit
in der Werkstatt in Meinerzhagen,
um pünktlich zu anstehenden
Lieferterminen verschiedene Maschinen und Anlagenkomponenten
qualitätsgerecht fertig zu stellen.
Das betrifft vor allem drei große
Aufträge: ein Kaltwalzwerk für
die Stahlindustrie, aber auch zwei
Besäum- und Längsteilanlagen für
die Aluminiumindustrie.
Bei einem Besuch der Werkstatt
von Danieli Fröhling in Meinerzhagen zeigte sich Geschäftsführer Jörg
Schröder mit der derzeitigen Auftragslage seines Unternehmens einigermaßen zufrieden: „Wir spüren,
dass wieder etwas Leben in den Markt
kommt, nachdem das vergangene
Jahr vielfach von Projektverschiebungen gekennzeichnet war. Inzwischen werden die in der Kupfer- und
Aluminiumbranche auf Eis gelegten
Projekte wieder aufgegriffen.“ Im
Edelstahl herrsche dagegen aufgrund
von erheblichen Überkapazitäten im
Markt noch immer Funkstille.
Die Impulse für Neuanlagen kommen weiterhin vor allem aus China,
sowohl auf der Kupfer- wie auf der
Aluminiumseite. Daneben bleibt
Südamerika aussichtsreich. So wurde
Danieli im vergangenen Jahr von Termomecanica São Paulo, dem Marktführer in der Herstellung von Langund Flachprodukten aus Kupfer und
Kupferlegierungen im südamerikanischen Markt, mit dem Bau eines
Vorwalz- und eines Fertigwalzwerks
für Bandbreiten bis 600 mm sowie
einer Fräse beauftragt. Der russische
Markt hat die Erwartungen, und zwar
der gesamten Branche, bisher nicht
erfüllt; hier sind kaum aktuelle Projekte in Bearbeitung. Der europäische
und deutsche Markt ist eher durch die
Modernisierung bestehender Anlagen
gekennzeichnet.
Danieli Fröhling konnte das vergangene Jahr ausgeglichener als ➝
43
Technologie
mancher Wettbewerber meistern. Da
die Auftragsbücher gut gefüllt waren,
gelang es dem Unternehmen, das Jahr
ohne Kurzarbeit zu fahren. In den
letzten eineinhalb Jahren wurden sogar 15 neue hoch qualifizierte Fachkräfte für alle Unternehmensbereiche
eingestellt. Einige der Ingenieure sind
in Poole angesiedelt, dem Centre of
Competence für die gesamte Aluminiumwalzwerkssparte bei Danieli
Fröhling.
Der Blick in die Werkstatt wird
zunächst dominiert von der Montage eines Quarto-Reversier-Kaltwalzwerks für hochfeste Stähle, das von
der österreichischen Böhler Uddenholm in Auftrag gegeben war. Die
Anlage ist für Bandbreiten von max.
670 mm und Coil-Gewichten von
16 Tonnen ausgelegt. Die Anlagengeschwindigkeit beträgt max. 800
m/min, die Walzkraft max. 12.000 kN
und die installierte Antriebsleistung
6.600 kW.
Daneben wird derzeit eine Hochgeschwindigkeits-Besäum- und Längsteilanlage für Shandong Nanshan
Aluminium Co., Ltd. und eine für
Shanghai Datun Energy Ressources
Co., Ltd. montiert, die beide für Aluminiumbänder der Legierungsgruppen 1xxx, 3xxx, 5xxx und 8xxx vorgesehen sind. Die Anlage für Shanghai
Datun ist für Banddicken zwischen
0,10 und 1,0 mm und Bandbreiten
zwischen 900 und 2.150 mm bei CoilGewichten bis 20,7 Tonnen ausgelegt.
Die Anlagengeschwindigkeit beträgt
max. 1.200 m/min, zum Einsatz
kommt eine CNC-Kreismesserschere,
Anzahl der Fertigstreifen: 2.
Die Anlage für Shandong Nanshan
ist für Banddicken zwischen 0,15 und
1,0 mm und für Bandbreiten zwischen 900 und 2.100 mm bei CoilGewichten bis 28 Tonnen ausgelegt.
Die Anlagengeschwindigkeit beträgt max. 1.500 m/min, zum Einsatz
kommen eine CNC-Besäumschere
und Längsteilschere, Anzahl der Fertigstreifen: 3.
Für die Besäum- und Längsteilanlage für Shandong Nanshan wird zudem eine elektro-statische Einölmaschine montiert, deren Highlight die
feine Zerstäubung und hohe Transportgeschwindigkeit des Ölfilms ist,
was wiederum zu einer gleichmäßigen
44
Ölverteilung auf der Bandoberfläche
führt. Das Tankvolumen beträgt 2
x 300 Liter, die Beschichtungsgeschwindigkeit 100 bis 400 mg/m2 je
Seite. Drei solcher Systeme befinden
sich bereits in Auftrag bzw. kurz vor
Beginn der Produktionsphase.
Danieli Fröhling sieht sich heute
aber nicht mehr als ein Komponentenhersteller für die Aluminiumindustrie, sondern tritt in Verbindung
mit den Schwesterfirmen Danieli Automation und Danieli Wean United als
Single-Source-Anbieter von schlüsselfertigen Komplettanlagen auf – von
Warmwalz- über Kaltwalz- bis hin zu
Folienwalzwerken mit allen dazugehörenden Behandlungseinheiten inklusive der kompletten Elektrik und
Automation.
Der Markenbegriff „Diamond Mill“
unterstreicht dabei den Anspruch des
Unternehmens, sich als Premiumanbieter mit hochwertigen Anlagen im
Markt zu etablieren. Die Kooperation
mit Innoval Technology, einem Spinoff der früheren Alcan mit Expertise
im Betreiben von Walzwerken, trägt
dazu bei, Walzwerkstechnik sowohl
aus Sicht des Maschinen- und Anlagenbauers wie auch aus Betreibersicht
zu konstruieren. Dies macht Danieli
gerade auch für Unternehmen interessant, die keine langjährige eigene
Erfahrung im Walzen von Aluminium
aufweisen. Hier kann der Partner Innoval das nötige Produkt- und Prozess-Knowhow einbringen.
Schröder betont bei diesem Anspruch, nicht auf Biegen und Brechen
an Ausschreibungen teilnehmen zu
wollen, um schnell eine Referenzanlage vorweisen zu können. „Wir
geben nur dort Angebote ab, wo wir
sicher sind, eine intensive Betreuung
des Kunden von Anfang der Projektphase an sicherstellen zu können“,
sagt er. Bei der Ausschreibung eines
Kaltwalzwerks in China war Danieli
Fröhling bis in die Endphase vertreten. Schröder unterstreicht, dass diese Ausschreibung eine hervorragende
Gelegenheit war, das „Diamond“Konzept praxisnah zu verfeinern und
auf den Kundenbedarf auszurichten.
Auch das Konzept für Folienwalzwerke wurde inzwischen so verfeinert,
dass man sich im Wettbewerb gut gerüstet sieht. Schröder nennt in ➝
highly qualified staff across the organisation as a whole. Some of the engineers are settled in Poole, the location
of the Centre of Competence for the
entire aluminium rolling plant sector
of Danieli Fröhling.
The view in the workshop is primarily dominated by the assembly of
a 4-high reversing cold mill for highstrength steels, ordered by Böhler
Uddenholm. The unit is designed for
strip widths up to 670 mm and coil
weights of 16 tonnes. The maximum
speed of the machine is 800 m/min,
the rolling force up to 12,000 kN and
the installed drive power is 6,600 kW.
In addition, at present a highspeed trimming and slitting machine
is being assembled for Shandong Nanshan Aluminium Co., Ltd and one for
Shanghai Datun Energy Resources
Co., Ltd, both of them for aluminium strips of the alloy groups 1xxx,
3xxx, 5xxx and 8xxx. The machine for
Shanghai Datun is designed for strip
thicknesses between 0.1 and 1.0 mm
and strip widths between 900 and
2,150 mm, with coil weights up to
20.7 tonnes. The maximum machine
speed is 1,200 m/min and it uses a
CNC circular blade shear. Number of
finished strips: 2.
The machine for Shandong Nanshan is designed for strip thicknesses
between 0.15 and 1.0 mm and strip
widths between 900 and 2,100 mm,
with coil weights up to 28 tonnes. The
max. machine speed is 1,500 m/min
and it uses a CNC trimming and slitting shear. Number of finished strips: 3.
For the Shandong Nanshan trimming and slitting unit an electrostatic
oiling machine is also being assembled, whose highlight is the fine
spraying and high transport speed of
the oil film, which in turn results in
uniform oil distribution over the strip
surface. The tank volume is 2 x 300
litres and the coating rate is 100 to
400 mg/m2 on each side. Three such
systems have already been ordered
or are shortly before the beginning of
their production phase.
What’s more, today Danieli Fröhling no longer regards itself as a component manufacturer for the aluminium industry, but rather, in combination with its sister companies Danieli
Automation and Danieli Wean ➝
ALUMINIUM · 3/2010
technologie
customer’s needs.
United, as a single-source supplier of
diesem Zusammenhang die technolocomplete,
turnkey
plants
–
from
hotgisch hochwertige Steuerung, mit der
The concept for foil mills has meanrolling, to cold- and foil rolling mills
sich verändernde Eingangsparameter
while also been refined to the point
in die Planheitsregelung gegenüber
that the company is well equipped to
with all the associated treatment units
compete. In this connection Schröder
heutigen Systemen wesentlich verbesand including the complete electrical
mentions the technologically highand
automation
and
process
systems.
sert werden. So werden die Eingangsgrade control system with which varThe trademark ‘Diamond Mill’
parameter für mathematische Modelying input parameters for the flatness
emphasises the company’s aim to
le durch das neu entwickelte ‘Hi-Res
regulation have been substantially
have established itself on the market
Spray System’ konstant gehalten und
improved compared with current sysas a premium supplier of high-grade
somit höhere Genauigkeiten über die
tems by applying the new developed
equipment.
Its
collaboration
with
InWalzzeit erreicht als bei traditionellen
‘Hi-Res Spray System’ and therefore
noval
Technology,
a
spin-off
from
Modelle. Neue Folienwalzwerke wird
quality fluctuations originating in that
the former Alcan with expertise in
es in Europa künftig seltener geben,
way are reduced for constant input
aber auch die Modernisierung bestethe operation of rolling plants, convalues for the mathematical models.
hender Anlagen ist für Danieli Fröhtributes much to the design of rolling
In Europe it is unlikely that
ling interessant, „weil man
new foil mills will often apdabei technologische Highpear in times to come, but for
lights setzen kann, womit wir
Danieli Fröhling the modunserem Anspruch als Preernisation of existing units
miumanbieter gerecht weris also interesting, “because
den können. Insofern ist das
in doing this one can achieve
Modernisierungsgeschäft ein
technological
highlights
attraktives Segment, das wir
which justify our claim to be
ebenfalls selektiv verfolgen“,
a premium supplier. Accordso Schröder.
ingly, modernisation busiImmer wichtiger beim
ness is an attractive sector
Bau von Walzwerken wird
which we also pursue selecdie nachgeschaltete Ablufttively”, Mr Schröder says.
reinigung. Auch in aufstre- Grafische Gesamtansicht der Besäum- und Längsteilanlage für
Abb.: Danieli Fröhling
benden Regionen wie Asien Shandong Nanshan Aluminium
Of continually increasing
und Südamerika gewinnt Overall view of the trimming and slitting unit for Shandong
importance when building
eine moderne Luftrein- Nanshan Aluminium
rolling plants is the downhaltetechnik mit strengen
stream exhaust air purificaEmissionsgrenzwerten wachsende
tion.
Even
in developing regions such
mill technology having regard to the
Bedeutung. Hier ist Danieli Fröhling
as Asia and South America modern
standpoints of both the machinery
vor kurzem eine exklusive Kooperaair purification technology with
and plant manufacturer and the option mit der Julius Montz GmbH aus
strict emission limit values is gainerator of the plant. This makes Danieli
ing importance. In this field Danieli
particularly
interesting
for
companies
Hilden eingegangen, die sich auf den
Fröhling recently set up an excluwhich
do
not
have
long
years
of
their
Vertrieb und die Weiterentwicklung
sive collaboration with Julius Montz
own experience in the field of aluminder DAN-ECO2-Systeme erstreckt.
GmbH in Hilden, which extends to
ium
rolling.
In
such
cases
the
partnerDas Unternehmen ist international für
the marketing and further developship
of
Innoval
can
provide
the
necesseine Konstruktion von Abluftreiniment of the DAN-ECO2 systems. The
sary product and production process
gungssystemen bekannt. DAN-ECO2
know-how.
wird zur effizienten Rückgewinnung
company is internationally known for
In this context Schröder stresses
und Rückführung von gebrauchtem
its design of exhaust air purification
that he has no wish to participate in
Walzöl in den Walzprozess eingesetzt
systems. DAN-ECO2 is used for the eftenders by hook or by crook in order
und schützt die Umwelt vor flüchficient recovery and refeeding of used
tigen organischen Verbindungen. Bei
rolling oil during the rolling process
to be able as quickly as possible to
einem Abgasstrom von 120.000 m3
and protects the environment from
point to reference plants. “We only
volatile organic compounds. With an
tender when we are confident that we
pro Stunde und 1.000 mgC/m3 reiexhaust gas flow of 120,000 m3 per
can serve the customer’s needs comnigt die Anlage mit einer Effizienz
pletely from the very beginning of the
von 99,95 Prozent. Eine solche Anhour and 1,000 mgC/m3, the unit
planning phase”, he says. In tendering
lage wird unter anderem im Hydropurifies with an efficiency of 99.95
for a cold mill in China Danieli FröhWalzwerk in Grevenbroich eingepercent. Such a unit is in use at the
ling was represented right up to the
setzt. Eine bessere Anlagenreferenz
Hydro rolling plant in Grevenbroich,
final phase. Schröder stresses that the
in einem Land, dessen Emissionsamong others. There can be no better
tender in question was an outstandgrenzwerte zu den strengsten in der
plant reference in a country whose
ing opportunity to further refine the
Welt zählen, kann es nicht geben.
emission limit values are among the
‘Diamond’
concept
and
adapt
it
to
the
strictest in the world.
■
■
46
ALUMINIUM · 3/2010
Technology
Technology breakthrough in the production of aluminium ingots
B. Rieth, Meerbusch
Track & Belt is the latest and the natural evolution of the casting wheel
technology, which decisively bears
the Properzi stamp and has proved its
worth for years. To give the dimensions usual for ingots, already since
the early 1990s the company adapted
the introduced and proven process by
enlarging and the cast cross-section
and the casting wheel diameter up
to 4.2 m for the production of ingots
from secondary aluminium. Whereas
the solidification process takes place
in the casting wheel around part of
the wheel circumference covering an
angle of 210 degrees with a U-shaped
mould cross-section covered by a circulating steel strip, in the case of Track
& Belt the casting wheel is replaced by
a mould made from a special copper
alloy, which is divided into a number
ALUMINIUM · 3/2010
of individual segments that follow
one another closely. The segments
are mounted on a circulating endless
chain and are moved in the solidification zone horizontally, interlocked
with one another. This succession
of segment can be ideally seen as a
casting wheel cut into small segments
with radius equal to ‘infinity’.
Thus, the length of the solidification zone is no longer determined by
the diameter of a casting wheel but
can be chosen freely, which results in
a substantial production performance
increase.
The tension chain with the mould
segments attached on it passes round
two gearwheels, one of which is driven, and pulls the individual moulds at
a speed which is adjustable in accordance with the solidification process
taking place in the solidification zone.
During this the mould blocks are covered by a circulating steel strip, so that
trapezium-shaped, emerges from the
machine. A secondary bar cooler provides further cooling of the bar down
to 450°C to 520°C before passing in
the down stream equipment. This is
first marked with all the data required
for identification, before being cut up
automatically by a rotary shear into
individual ingots with a reproducible length, usually 720 mm, with a
tolerance of ±0.5 percent. The ingots
are cooled in a cooling tunnel down
to 60° to 70°C and then automatically stacked in layers by a Cartesian
stacker, strapped and labelled.
Compared with ingots cast conventionally in open moulds, those
produced by a Track & Belt unit differ in having smooth and flat surfaces
on which no moisture collects during
storage. They are also free from dross
inclusions and cavities. The stacks,
with several layers offset relative to
one another by 90 degrees, are of stable shape and require very little effort
to strap. Besides, several stacks can be
stored one on top of another.
Must aluminium ingots
always weight 22.7 kg?
Photos: Vedani Carlo Metalli
Ingots are the most usual form in
which, after melting, aluminium
is supplied to the industry. Such
ingots have long been produced
in horizontal, trapezium-shaped
moulds open at the top, of which
several are connected to one another to form endless units, and go
through a discontinuous casting
process in cycles. The standard
size of 50 lb (22.7 kg) has become
established on the market. The
Italian manufacturer ContinuusProperzi S.p.A., successful since
the 1940s all over the world in the
development and production of
more than 300 continuous casting
and direct rolling systems for the
production of non ferrous wire
rod, has years ago been seeking
a method for producing ingots
continuously as sections of an
endlessly cast strand. From an
intermediate step with a casting
wheel diameter enlarged to 4.2
metres, a new technological concept called ‘Track & Belt’ has been
developed. In this, smooth and
safely stackable aluminium ingots
are produced from a horizontally
cast endless strand, cut into reproducible lengths with close tolerance limits.
View of a Properzi Track & Belt line in
operation
a temporarily closed mould cross-section is created. The molten metal flows
in a controlled way, automatically
and free from turbulence, out of the
tundish and into the moulds formed
by the copper segments and the steel
strip. External cooling-water nozzles
arranged on all sides ensure rapid and
uniformly controlled solidification. At
the end of the horizontal solidification
stretch a cast strand, already straight
by virtue of the casting process and
On this point we spoke to Carmelo
Maria Brocato, commercial director
at Continuus-Properzi.
ALUMINIUM: What caused Properzi
to call into question the shape and
weight of aluminium ingots that have
been customary for so many years?
Brocato: That began in the 1990s,
when the Italian company Raffmetal,
which has since grown to become the
largest refiner in Europe, was looking for a more efficient system for
producing ingots weighing 8.5 kg. For
Properzi, therefore, it was clear from
the start that in connection with the
development of a new technology a
way also had to be found to eliminate
the known problems associated with
open-mould casting, in other words
dross inclusions, cavities and limited
reproducibility of the dimensions and
weight.
ALUMINIUM: How much were you
able to have recourse to your tried ➝
47
Technology
and tested casting wheel technology?
Brocato: As you know, our continuously-operating casting wheels were
originally designed for the production of pre-material for aluminium
and copper wires, in other words for
comparatively small cross-sections
and production quantities. Larger
cross-sections and higher throughput performances require as a first
step that the mould cross-section and
the necessary solidification zone are
made larger. This was achieved by increasing the casting wheel diameter
to 4.2 metres. A casting wheel of that
size produces an aluminium bar with
a cross-section of up to 5,500 mm2. A
downstream rotary shear cuts the cast
strand into bars, in other words ingots,
with a reproducible length and a tolerance of ±0.5 percent. The capacity
of the 4.2 m casting wheel is up to 20
tonnes per hour; considering ingots of
10 kg we are talking of 2,000 ingots
per hour. No skimming is needed and
the ingots are flat and smooth, with no
cavities and no cracks.
ALUMINIUM: That was already a big
step forward, but did it achieve your
development objective?
Brocato: For the refiner market, at first
it did. Raffmetal ordered two more
ingot casting wheels at intervals of a
few years. At the end of the 1990s the
Italian company Sacal too installed
two complete in-line casting lines
equipped with an automatic stacking
and strapping station.
ALUMINIUM: How did the primary
smelters rate your development?
Brocato: From the beginning there
was a lot of interest, with the result
that in 2005 Dubal, as art of its ‘Kestrel’ expansion project, began operating a high-performance casting plant
for ingots supplied by ContinuusProperzi, which included the packaging equipment, in other words the
stacker, weighing machine and the
strapping and labelling equipment.
The plant produces 10-kg ingots at a
rate of 2,000 per hour for unalloyed
aluminium and 1,500 per hour for alloys with a high silicon content. At the
same time we supplied similar plant
with comparable performance to Alba
in Bahrain.
ALUMINIUM: What happened next?
Brocato: The quality advantages compared with conventionally produced
ingots could not disguise the fact that
the plant production performance
attainable was largely determined
by the casting wheel diameter. So to
boost the output of the plant to over
2,000 ingots per hour, we would have
had to increase the casting wheel
diameter to more than 4.2 metres,
which we did not regard as desirable
for various reasons.
ALUMINIUM: What alternatives did
you have?
Brocato: It made no sense to keep increasing the casting wheel diameter in
order to adapt the length of the solidification zone to achieve the required
capacity boost. Our considerations
therefore led to the solution of choosing an ‘infinitely’ large casting radius
but in doing this, keeping the size of
the plant, namely its height, within
reasonable limits (see the preceding
article).
ALUMINIUM: How has the Track &
Business Contact
Successful for many years,
aluminium sales team from southern Germany
seeks a new challenge. Our team has a very good
knowledge of the southern German market and
relationship with customers in European submarkets.
Wanted is a business relationship to an extrusion
plant. The establishment of a complete wholesale
branch or a plant stock trading is conceivable.
Please reply to box-number AL-1766 at Giesel
Verlag GmbH, Rehkamp 3, D-30916 Isernhagen.
48
Belt system been received by the market so far?
Brocato: The first unit began operating during the year 2005 at the company Carlo Vedani Metalli in Milan.
This was followed by further units
at Raffmetal and Raffineria Metalli
Capra in Brescia, Raffmetal still prefers the light ingots of 8.5 kg.
ALUMINIUM: How do you view the
future of the new system, bearing in
mind the smaller weight of the individual ingots?
Brocato: The Track & Belt system is
View of Properzi bundles before strapping
(one tonne approximately)
attracting a lot of interest, both in the
field of aluminium recycling and from
aluminium smelters. From the productivity standpoint we see that 30 lb
(= 13.6 kg) ingots are gaining ground.
Taking the quality advantages into account as well, which ultimately also
translate into increased productivity,
with the Track & Belt system for 30-lb
ingots and a capacity of 28 tonnes
per hour we are exactly at the point
toward which the market is tending.
With the data available in our records,
and also taking advantage of the experience in the wire rod sector, where
the equipment is much more complex
and more maintenance demanding,
we know that an overall efficiency
of our equipment of 85 percent is a
realistic data and the production expected for a line of 28 tph (30 lbs/13.6
kg ingots) is close to 170,000 tpy considering 300 working days a year.
Last but not least, the idea of 30
lbs/13.6 kg originated by our chairman – Mr Giulio Properzi – finds his
ground on the necessity of giving better working conditions to those users
of ingots who, having small size furnaces, are obliged to handle singular
ingots manually.
■
ALUMINIUM · 3/2010
co m pa n y n e w s w o r l d w i d e
aluminium smelting industry
The whole energy situation in Venezuela is dramatic. Any further cuts
to Bauxilum output are a threat to the
country’s whole aluminium industry.
Norsk Hydro
chinalco may build
aluminium smelter in Gansu
alcoa and Bpa reach power
supply accord for intalco smelter
Alcoa and the Bonneville Power Administration (BPA) have reached an
agreement to provide power for the
Intalco aluminium smelter in Ferndale/Washington. The new contract
provides Alcoa with up to 320 MW of
power at the Industrial Power (IP) rate
and will allow the plant to produce a
total of 184,000 tpy. Alcoa is a 70-year
customer of BPA and this contract
marks a return to direct power sales
under the Northwest Power Act. Direct power sales were halted in 2006.
The new contract has two phases: an
immediate 17-month power supply
for up to 320 MW, and a second phase
for at least an additional five years of
power. The second phase would be
implemented following clarification
of a recent US 9th Circuit Court of Appeals ruling and will depend on the
state of future power markets.
Venezuela cuts steel and
aluminium output to save power
Venezuela will chop output at its leading steel mill and at two aluminium
smelters (Alcasa and Venalum) to
reduce energy consumption by about
558 MW. The cuts are due to falling
water levels at the Guri hydroelectric
dam which supplies about 70% of the
country’s electricity. At Alcasa, the
government will shut two production
lines permanently and will focus on
ALUMINIUM · 3/2010
increasing production at two other
lines via investment. For the moment,
this shutdown would cut production
by about 1,600 tpm. The cutbacks
would reduce consumption by about
58 MW at Alcasa and by about 300
MW at Venalum.
The Venezuelan government will
install thermoelectric plants to supply energy to the country’s stateowned primary aluminium producer
CVG Venalum. Plants with capacity
to generate 100 MW capacity will
feed Venalum. Venalum has made
further cuts to production by shutting another 33 electrolytic cells at
its plant in addition to the initial 360
cells. Venalum’s output will fall by almost 50% in 2010 to around 220,000
tonnes if the cells remain idle.
CVG Alcasa, also a state-owned
company with capacity to produce
200,000 tpy, has closed more than
430 out of 680 cells. The Venezuelan government will cut the power
supplied to state-owned bauxite and
alumina producer CVG Bauxilum by
50% as part of its national power saving plan. The government told CVG
Bauxilum to save half the energy it
consumes, from 45 MW to 22.5 MW.
Bauxilum would have to invest a
further USD284m to produce 1.65m
tonnes of alumina in 2010, and then to
reach its installed capability of 2m tpy
in the following years. But the company only produced 1.37m tonnes in
2009 and would not even reach an
output of 1 million tonnes in 2010 if
the 50% energy cut is implemented.
Aluminium Corp. of China (Chinalco)
may build a smelter in Qingyang city,
Gansu province, boosting capacity
by more than 10%. Chinalco seeks
to invest in alumina and aluminium
capacity in energy- and resource-rich
areas in China and overseas. The city
government and Chinalco had signed
a framework agreement to build a
500,000 tpy aluminium smelter and
develop a coal mine. Details of the aluminium smelter project would be finalised in 2010. The Qingyang smelter
project could be built and operated by
Chalco. If built, the Qingyang smelter
will be Chalco’s fourth smelting facility in the northwestern province.
But getting central government
approval may be a struggle, as Beijing looks to close 800,000 tpy of old
smelting capacity by the end of 2010,
and has said that in principle it will
not approve any new smelters in 2009
to 2011 as the country already has
more capacity than it needs. Chinalco would also develop a mine with
proven reserves of 102m tonnes of
coal, an essential material for energy-intensive aluminium production.
Coal-rich Qingyang city has 10.4bn
tonnes of proven coal reserves.
india’s nalco plans
new refinery and smelter
India’s state-run Nalco wants to set
up mines and a refinery project in the
southern Andhra Pradesh state and
to add a second aluminium smelter
in the eastern state of Orissa, according to the government. Nalco plans to
spend 57bn rupees (USD1.2bn) in the
Andhra Pradesh project and 163.5bn
rupees (USD3.44bn) in Orissa for the
smelter and for a captive power plant.
The proposed aluminium smelter
would have a capacity of 500,000
tpy and would be completed in two
phases.
➝
49
co m pa n y n e w s w o r l d w i d e
At the end of December 2009, the expansion at Hindalco’s Muri refinery
and Hirakud smelter in Orissa resulted in a 50% rise in alumina production
at Muri and a 12% increase in metal
production at Hirakud. The Hirakud
smelter’s expansion to 155,000 tpy
capacity from 143,000 tpy has been
completed on time and work on expanding the smelter to 213,000 tpy
from 155,000 tpy is under way. The
initial capacity expansion phase to
161,000 tpy will be completed by July.
Hindalco’s 1.5m tpy Utkal Alumina
project at Rayagada, Orissa, is expected to be complete by July 2011. The
company’s Aditya aluminium project
in Orissa, which includes a 1.5m tpy
alumina refinery, a 359,000 tpy aluminium smelter and a 900 MW captive power plant, is expected to come
on stream by October 2011. The Mahan aluminium project, which is being built in the central Indian state of
Madhya Pradesh, will start production
by July 2011. Its 359,000 tpy capacity
Jharkhand aluminium smelter project
at Sonahatu in the eastern state of
Jharkhand is still in the land acquisition stage. It is expected to come on
stream by June 2013.
Bosnia’s aluminij mostar sees
better 2010 after tough year
Bosnia’s sole aluminium smelter expects an improved 2010, due to expanding demand and rising global
prices, after posting a 30% decline
in revenues and flat profit in 2009.
The smelter produced 96,000 tonnes
of primary aluminium in 2009, down
from 123,000 tonnes in 2008, after
cutting output by a quarter last year.
The smelter gradually started returning to full production in autumn last
year. It produces anodes, billets, wire,
ingots, T-bars and slabs used in the
metal, construction and car industries, which have been hard hit by the
global economic crisis. Its full capacity is 135,000 tpy.
Its revenues and exports fell by a
third in 2009 to close to 138m Bosnian
marka (USD103m) and 260m marka
50
respectively. The company had earlier said that its annual production
could reach 300,000 tonnes if plans
to build a plant for aluminium waste
recycling and electrolysis went ahead.
The plans can proceed only after the
company has been privatised and has
found a power supplier offering favourable electricity prices.
The government of the MuslimCroat federation, an autonomous region that makes up Bosnia along with
the Serb Republic, extended until May
a deadline for the sell-off of an 88%
stake in Aluminij Mostar – held half
by the company and half by the government. This is the fourth extension
since 2007; it was made to give more
time to resolve some outstanding issues. The sale of Aluminij Mostar
to the best bidder, a consortium led
by Swiss-based commodities trader
Glencore International, has been
stalled over high electricity prices and
environmental and ownership issues.
Vedanta resources phased out
soderberg capacities in india
Aluminium production at its Balco
subsidiary fell 30% y-o-y during the
quarter to 65,000 tonnes as the company shut its 100,000 tpy smelter to
set up a new one with a capacity of
325,000 tpy. The new smelter is expected to be operational by the third
quarter of the next financial year.
The company’s Vedanta Aluminium
project in Orissa, in which it holds
a 25% stake, was commissioned in
November 2009 and has a capacity of
225,000 tpy. The second phase of the
project with a similar capacity will be
operational by March. Sterlite’s parent company, Vedanta Resources,
holds the remaining 75% stake in
Vedanta Aluminium.
nalco to hit expanded
460,000 tpy capacity in 2010
India’s National Aluminium Co. (Nalco) plans to reach its full expanded
capacity of 460,000 tpy of aluminium
in 2010. Nalco commissioned all 240
aluminium potlines in mid-December
and plans to produce around 39,000
tpm for the year. Aluminium exports
may also increase from just over
100,000 tpy. Arrangements are being
made to import coal to build up stocks.
Nalco has completed its expansion
of bauxite mining capacity from 4.8m
to 6.3m tpy but has yet to reach full
production of alumina, because Maoist attacks delayed work on the refinery expansion. This expansion from
1.57m to 2.1m tpy is now expected to
be finished by December 2010. The
expanded power capacity from 960
MW to 1,200 MW will be fully operational when the last 120 MW power
plant starts up in March.
■
Bauxite and alumina activities
Alunorte
Hindalco’s expansion
projects make headway
windalco to lay off 762 employees
UC Rusal will cut 762 more jobs at its
majority owned West Indies Alumina
Co. (Windalco) in Jamaica. The layoffs
will be completed by March and were
ALUMINIUM · 3/2010
co m pa n y n e w s w o r l d w i d e
demanded by the Refinery’s employees, who are being paid a three-day
week but preferred to receive severance packages and to find work elsewhere. The decision to lay off most
of its remaining work force comes
nine months after Rusal suspended
production at its Kirkvine and Ewarton refineries, along with output at
Alumina Partners of Jamaica (Apart),
under the weight of sluggish alumina
demand.
Market impact is, however, expected
to be limited as inventories are high
and alumina prices are expected to
fall as a result of weak buying. Nanchuan Alumina mainly supplies to
110,000 tpy Aba Aluminium in Sichuan province, and both are whollyowned subsidies of private company
Bosai Group.
Aba Aluminium has also felt the
power supply tightness but is willing
to pay a price to maintain production.
Both Nanchuan Alumina and Aba
Aluminium plan to expand in 2010.
Nanchuan Alumina plans to boost
alumina capacity by 150% to 500,000
tpy by May or June, while Aba Aluminum plans to start commissioning
90,000 tpy of new capacity at the end
of May. Most of Aba Aluminium’s
expanded alumina needs will be supplied by Nanchuan Alumina.
■
recycling and secondary smelting
China’s Yankuang Corp. has taken an
8.42% stake in Bauxite Resources for
9.85m Australian dollars (USD9m),
following approval from Australia’s
Foreign Investment Review Board
(FIRB). FIRB also approved the companies 50 : 50 bauxite-to-alumina joint
venture that aims to generate 150 to
300m tonnes of refinery grade bauxite.
In October 2009, Yankuang took over
100% of major Australia coal producer Felix Resources through its Australian subsidiary Yancoal Australia.
Yankuang, based in eastern Shandong
province, produces mainly coal and
more than 140,000 tpy of aluminium.
Hydro
yankuang takes 8% stake
in Bauxite resources
India’s JSW Aluminium secured 4.2m
tpy of bauxite from the Andhra Pradesh state government for a proposed
1.2m tpy alumina refinery. The bauxite
price will be based on the LME price
and equipment orders will be placed
from April for the Rs45bn (USD973m)
alumina refinery in Viziayanagram
district. Only state companies can
mine bauxite in Andhra Pradesh so
JSW’s supply will come from Andhra
Pradesh State Mineral Corp.
Two recycling smelters in Mount
Pleasant, Tennessee, have failed to
convince the City’s Planning Commission to rezone a 90 acre parcel for
disposal of salt cake and baghouse
material. Local disposal would cut
costs and allow for the possibility of
salt cake recycling as technology develops. Tennessee Aluminum Processors and Smelter Service Corporation will continue to have access to
the state-approved disposal facilities
they now use. An earlier landfill for
smelter waste existed nearby but was
shut down in the mid-1990s.
ium remelt plant in Taiwan with a capacity of 75,000 tpy of extrusion ingot.
Taiwan is the third-largest extrusion
market in Asia, with a total extrusion
ingot consumption of about 400,000
tonnes.
The remaining ownership of the
Famco aluminium remelt plant will
continue to be held by the holding
company E-Tech, in which Lawrence
Cho is the main shareholder. Famco
is located in the Yunlin Industrial Estate in Yunlin County, along Taiwan’s
western coast. The plants equipment
allows for efficient production of a
wide product range, including diameters ranging from four to nine inches,
as well as special alloys.
nanchuan alumina
cuts output by a third
Hydro increases ownership
in Taiwan remelt plant
Kaye presteigne goes
into receivership
China’s Nanchuan Alumina Refinery
in southwestern Chongqing city is
operating at two-thirds of its 200,000
tpy capacity due to insufficient power.
Hydro has signed an agreement to increase its ownership stake in Famco
from currently 45% to a controlling
majority stake. Famco is an alumin-
UK aluminium diecaster Kaye Engineering, which trades as Kaye Presteigne, goes into receivership. Brian
Johnson and David Birne of Fish- ➝
Jsw secures bauxite for
1.2m tpy alumina project
ALUMINIUM · 3/2010
aluminium smelters rebuffed
on salt cake landfill in Tennessee
51
co m pa n y n e w s w o r l d w i d e
er Partners in London were appointed
to administrators. Kaye Presteigne,
like other diecasters in the country,
has been under pressure from a lack
of credit insurance and raw material
price volatility. Lack of credit insurance and financing have weighed
heavily on the secondary aluminium
sector since the global recession hit.
Diecasters, which traditionally
buy their aluminium alloy on longterm contracts, have struggled to
pass on the dramatic rises in raw material costs since demand returned.
LM24 diecasting ingot rose to trade
at £1,280-1,330 (USD2,083-2,165) per
tonne in mid-January, its highest level
since October 2008. This represents
an increase of almost 70% since February 2009 when LM24 was trading
at USD790-900 per tonne. As a result,
several diecasters have to pay more
for their aluminium alloy than their
customers have agreed to pay for their
end product.
Kaye Presteigne, based in Powys,
Wales, was formed in 2006, when its
US parent company JL French filed
for Chapter 11 bankruptcy protection
and the administrators sold off the
business. Its high-pressure foundry
operates 16 machines, with capacities ranging from 200 tonnes to 750
tonnes, and produces castings ranging in weight from 5 grams to 5 kg.
In addition, the gravity-casting facility includes a fully-automated in-line
gravity plant, capable of producing
more than 1m castings a year. Peter
Neagle, Paul Davidson and Geoffrey
Smith are listed as Kaye Engineering
directors, and solicitor John Bailey as
company secretary.
■
aluminium semis
its Warrick operations in Newburgh/
Indiana, before the end of the first
quarter. The cuts represent a nearly
10% staffing reduction for the 1,000
employee division in Tennessee. The
staffing reductions are the result of
reduced can sheet demand in 2010.
Alcoa is working with union leaders
to offer early retirement packages to
reduce the number of involuntary layoffs that will have to take place.
sapa installs extrusion press
at cressona facility
Sapa Holding and the United Steelworkers union have signed a new collective bargaining contract for about
600 hourly employees at the Sapa
Extrusions plant in Cressona/Pennsylvania. The contract, which will run
through November 2013, includes
wage increases in each year and a
restructured health benefits package.
Sapa Extrusions operates five plants
in Cressona, Connersville, Elkhart
and Kokomo, all located in Indiana,
and Spanish Fork/Utah. The Cressona operation is installing a 3,600tonne direct-extrusion press that can
extrude 254 mm billets to produce
profiles with up to a 254 mm circle
size. The installation costs about
USD4m, with start-up projected for
the third quarter of 2010.
soUTH america
Alba
cabelum’s aluminium
supply down 70%
norTH america
is a wholly owned subsidiary of global
miner Rio Tinto.
alcan cable to shed more jobs
Alcan Cable will lay off 33 employees from its Roseburg/Oregon facility in response to a difficult market
environment. The layoffs are part of
the Worker Notification and Retraining Notification (WARN) Act and are
the second round for the facility. In
April 2009, the company had already
announced 32 layoffs at the same
plant. Alcan Cable, based in Atlanta,
52
alcoa to lay off
staff from can sheet plants
Alcoa will lay off some 235 employees
from the Rigid Packaging division in
the first quarter in response to lowerthan-anticipated sales projections
for the year. The company will slash
some 90 jobs at the Tennessee operations near Knoxville and 145 jobs at
The aluminium supply at Venezuelan
cable producer Cabelum has dropped
some 70% because of two production
lines that were shut down at aluminium smelter Alcasa and the 360 cells
that were stopped at aluminium smelter Venalum. Under normal conditions
the company receives 1,800 tpm of
aluminium and now this has fallen to
around 600 tpm. The government’s
goal is to provide each transforming
company with only the aluminium
needed to operate at minimum capacity. Cabelum has installed capacity to
transform 2,000 tpm of aluminium.
ALUMINIUM · 3/2010
co m pa n y n e w s w o r l d w i d e
In November 2009, Cabelum started
the second phase of an expansion
project worth USD11.6m which includes the installation of drawn wire
and cabling machinery that will increase production to 30,000 tpy.
With the increased production, the
company could start exporting to
markets like Chile, Brazil and Bolivia.
Cabelum, Alcasa and Venalum are all
state controlled.
alcoa recognised by
Honda for quality
Alcoa Latin America’s Utinga plant
in Santo André, Brazil, was recognised by Honda Motorcycle of Brazil
for outstanding quality performance.
Alcoa received Honda’s top quality supplier award following Honda’s
thorough assessment of its supplier
network in Latin America over a 12month period.
Alcoa is the exclusive supplier of
extruded aluminium tubes for the rear
suspension of several of Honda’s popular motorcycles for the Latin American market. By using Alcoa’s lighter,
high-strength 7xxx series aluminium
alloy in the suspension system, Honda
improved the motorcycle’s performance significantly by reducing the
weight of the swing arm, meeting
customer’s expectation. The Utinga
plant supplies extrusions to a number
of Latin American market segments,
including the ground transportation,
industrial machinery and electrical
equipment markets.
alucasa output expected to drop
Output at Venezuelan state aluminium products company Aluminios
Carabobo (Alucasa) could drop by
40% because of the production lines
that were shut down at the aluminium smelter. Alcasa is Alucasa’s main
raw materials supplier, and now that
two of its production lines have been
closed it will not be able to provide the
needed aluminium. The closure significantly lowers the 1,000 tpm of aluminium that Alucasa had been receiving. Now only about 600 tonnes will
come in, which will seriously reduce
production levels. Both Alucasa and
Alcasa are controlled by state heavy
industry holding company CVG. The
Alucasa plant has installed capacity of
23,000 tpy and as of October was producing at a rate of only 8,400 tpy.
In December, the Venezuelan
basic industry and mining ministry
(Mibam) lowered the power supply
available at state industry plants in the
Guayana region, so that Alcasa had to
shut down production lines 1 and 2
as part of the procedure. In November and December, Alucasa produced
1,300 tonnes of thin sheet aluminium
products. In October, Alucasa was
operating at less than 40% of its capacity due to a lack of investments in
technology, and workers petitioned
the government to provide a rescue
plan in order to avoid a deeper crisis
and subsequent closing.
Meanwhile, the Venezuelan government has promised to contribute
USD150m to start the first stage of installing a new fabrication line at state
aluminium smelter Alcasa. The government has also guaranteed that all
workers from production lines 1 and
2 will still have jobs and has promised
to pay all benefits. The workers were
left unemployed when production
lines 1 and 2 closed down, and are
studying the possibility of dismantling
these lines and installing a new plant.
We purchase and supply:
n Rolling mills cold/hot
n Roll grinding machines
n Continuous casters
n Levellers/straighteners
n Drawing machines
n Slitting lines
n Cut-to-length lines
n Coilers
n Coil carriages
n Rollformers
n Tube welding machines
n Extrusion presses
n Joining presses
n Packing lines for strips
Please ask for our sales list!
COILTEC Maschinenvertriebs GmbH · Silberkaute 4 · 57258 Freudenberg
Phone +49 (0) 2734/271190 · Fax +49 (0) 2734/271195
www.coiltec.de · email: info@coiltec.de
ALUMINIUM · 3/2010
There are two proposals on how to go
about the transformation process, one
for rolling and the other for extruding, for which Alcasa already has the
resources needed.
eUrope
armenal produces over
20,000 tpy of thin foil
for first time in history
UC Rusal announced that, for the first
time since its commissioning, the Armenal plant produced and sold over
20,000 tpy of aluminium foil, nearly
twice as much as in 2008. In 2009,
the mill significantly improved labour efficiency and almost doubled
its productivity rate per employee.
Armenal’s yield ratio, currently exceeding 70%, stabilised, and the rate
of production rejects fell to 3%, which
is also the best figure ever achieved by
the foil mill.
Since January 2009, Armenal has
fulfilled nearly 1,500 export orders
and launched full-scale production of
ultra-thin foil, which is designed for
further gauging. Having improved the
quality of foil roll cutting by upgrading the cutting plant, the foil mill has
started to produce narrow-width 40
to 50 mm foil, which is in high demand in the global markets.
Hydro’s divestment of
spanish rolling mill completed
The sale of Hydro’s rolled products
Inasa plant in Irurtzun, Spain, was finalised at the end of December 2009.
The plant near Pamplona is now
operated by Bavaria Industriekapital AG under the name Inasa Foil
SA. As announced in December, the
transaction is cash-neutral for Hydro,
which will record an after-tax book
loss of about NOK200m (USD35m) in
its fourth-quarter 2009 results. The
plant, with more than 200 employees and a capacity of 30,000 tpy, had
been part of Hydro’s Rolled Products
business, which remains a leading,
worldwide supplier of rolled aluminium products, shipping up to ➝
53
co m pa n y n e w s w o r l d w i d e
1m tpy and employing a workforce
of around 4,000. Hydro will continue
serving Spanish customers of rolled
aluminium products through its sales
office in Barcelona.
Hydro selling
Hydro Trans to sKa invest
Norwegian investment company SKA
Invest has entered into an agreement
to buy Hydro Trans, which has activities in Norway, Finland and Denmark.
Hydro Trans is a Nordic supplier of
aluminium systems for heavy transport. The company, wholly owned by
Hydro, has 20 employees at production sites in Norway and Denmark,
and a sales office in Finland.
In 2009, Hydro Trans delivered
650 tonnes of aluminium-based systems. It has a market share of about
20%. SKA Invest has earlier acquired
other businesses from Hydro, namely
Hydal and Extrusions Tools. Both
have experienced good development.
The transaction, to be completed 1
March, is dependent upon approval
by competition authorities.
alcan packaging sale finalised
Rio Tinto announced that it completed the sale of the Alcan Packag-
The author
The author, Dipl.-Ing. R. P. Pawlek,
is founder of TS+C, Technical Info
Services and Consulting, Sierre
(Switzerland), a new service for the
primary aluminium industry. He is also
the publisher of the standard works
Alumina Refineries and Producers of
the World and Primary Aluminium
Smelters and Producers of the World.
These reference works are continually
updated and contain useful technical and economic information on all
alumina refineries and primary aluminium smelters of the world. They
are available as loose-leaf files and/or
CD-ROMs from the Aluminium-Verlag,
Marketing & Kommunikation GmbH
in Düsseldorf, Germany.
54
ing global pharmaceuticals, global
tobacco, food Europe and food Asia
divisions to Amcor for a total consideration of USD1.95bn. In August 2009,
Rio Tinto announced the receipt of a
binding offer from Amcor for these
businesses for a total consideration
of USD2.03bn. The transaction has
clearance from the European Commission and awaits clearance from
the Department of Justice in the
US. The completion of this complex
transaction is another significant step
in the recapitalisation of Rio’s balance
sheet. Since the start of 2009 Rio completed divestments of USD5.6bn despite a difficult environment created
by the global economic crisis. Since
February 2008, Rio has announced
asset sales of USD10.3bn.
■
supplier
aBB successfully commissioned
rectifier stations at Qatalum
Twenty-eight months after the 140m
US-dollar contract between Qatalum
and ABB was signed, power and automation technology group ABB success-
fully commissioned ten complete rectifier units at Qatalum’s primary aluminium plant. Handover of the plant
to the customer took place in midDecember 2009. ABB acted as EPC
contractor for the rectifier stations
and was responsible for engineering,
civil design, material delivery, training, documentation, installation and
commissioning. The scope of supply
included ten high voltage rectifier
units (each 1650 V, 85 kA) including
control and protection systems, two
DC collector busbar systems (each
340 kA) including ABB’s fibre optic
current sensor (FOCS), ten regulating
and rectifier transformers including
reactive power and harmonic filtering
systems, two SCADA systems (Supervisory Control And Data Acquisition),
as well as redundant auxiliary systems
(transformers, low voltage distribution, motor control centres, battery
systems, uninterruptible power supply, fire alarm and extinction systems,
air-conditioning). ABB also delivered
and installed 47 kilometres of high
voltage cables (220 kV) to connect
the rectifier stations to the dedicated
1,250 MW power plant.
■
on the move
Alcoa appointed Nicholas Ashooh vice
president, Corporate Affairs. He will be a
member of the Alcoa Executive Council
and have oversight for global communications, government affairs, community
relations and the Alcoa Foundation. Mr
Ashooh succeeds John D. Bergen, who
has been appointed vice president, Human
Resources.
UC Rusal announced a management
reshuffle in its aluminium division: Eugueny Zhukov, who previously held the
position of managing director of the Krasnoyarsk smelter (KrAZ), was appointed
general director of the Urals aluminium
smelter (UAZ). Mr Zhukov will be replaced
by Eugueny Nikitin, the former managing
director of the Sayanogorsk smelter (SAZ).
Meanwhile, Boris Smolyanitsky, who had
been managing UAZ for nine years, was
appointed adviser to lead the aluminium
division. Anton Savchenko, who had been
the financial director of the Sayanogorsk
smelter since 2006 after joining the
smelter in 1996, will be acting managing
director of SAZ.
Jean-Marc Noe, director of alumina
sales at Rusal, has left the Russian aluminium producer. Alexei Gordymov will
take over as a commercial director of the
alumina division.
Alba’s manager (Infrastructure and
Engineering) Ahmed Mohammed Al
Hashimi has been appointed chairman
of the Bahrain Occupational Standards
Review Committee. Alba’s Public Relations
manager, Khalid Jassim Bomtaia, has left
the company. Alba’s Human Resources
manager, Abdulrahman Janahi, takes over
the Public Relations department as acting
manager till further notice.
The BHP Billiton board announced
the retirement of Paul Anderson and Gail
de Planque from the board. Mr Malcolm
Broomhead and Ms Carolyn Hewson have
been appointed as non-executive directors.
ALUMINIUM · 3/2010
research
Innovative joining methods for lightweight designs, Part II*
Michael Marré 1, Christian Weddeling 1, Thilo Hammers 2, Matthias Merzkirch 2, Jens Rautenberg 3,
Prof. Dr.-Ing. Erman Tekkaya 1, Prof. Dr.-Ing. Volker Schulze 2, Prof. Dr.-Ing. Dirk Biermann 3,
Dr.-Ing. Dipl.-Inform. Andreas Zabel 3
Methods and procedures: The complexity of the lightweight nodes and
their requirements of geometric accuracy and surface quality need precise process planning and adequate
machining set-up for manufacturing.
Multi-axis machining set-ups provide
a high flexibility in development and
realisation. They allow milling, drilling, threading and reaming of the
nodes from five sides, depending on
the machining system being used. The
decrease in the number of changes to
the clamping set-up avoids interactive
defects and geometric inaccuracies
and therefore increases the economic
efficiency of the process.
From a given CAD model of the
frame structure with all the necessary
elements, the models of the nodes can
be used for further planning (Fig. 1).
The CAM system, as used for the manufacturing of complex parts like dies
and moulds, allows the generation of
machine specific NC data, depending
on which element or surface should
be manufactured and which tools and
cutting parameters should be used. A
Deckel-Maho 5-axis milling and machining centre (DMU 50 Evolution)
was chosen to manufacture the lightweight node and its integrated structured surfaces.
There are two basic ways to structure the surface of a joining zone. The
micro structure can be described by
characteristic surface parameters,
e. g. average surface roughness, core
roughness depth, or the contact area
percentage. This is important for a
tight fit between the inner and the
outer specimen [20]. Macrostructures
can be seen as pockets, grooves and
nuts, which allow the profile to fit into
* Part I of this paper, focusing on friction stir
welding and bifocal hybrid laser welding, was
published in ALUMINIUM 1-2/2010.
ALUMINIUM ·3/2010
Images: IUL / iwk I
Joining by hydroforming
and electromagnetic expansion
Fig. 1: Process chain for joining of frame structures
or onto the node to obtain a form-fit.
The transition between both types of
surface characteristics is smooth, with
the definition within this article being
that macro structures have a visible
depth (> 50 μm) and micro structures
are only measurable (< 50 μm) but not
visible. The micro structured surfaces
lead to a more interference-fit-based
connection due to the influence of the
friction and tangential stresses between both joined elements. Macrostructured surfaces allow a form-fit
joint.
It must be taken into account, however, that the degree of deformation
depends on both the material characteristics and the shape (depth, width,
length) of the formed element. For the
purpose of process-safe, economic,
and flexible milling, coated standard
ball end mills aluminium were chosen to mill the aluminium. Helical tool
paths for the simultaneous five-axis
finishing strategies help to keep constant engagement conditions between
tool and work piece in order to produce a homogeneous, constant ➝
Fig. 2: Process of joining by dieless hydroforming
55
research
surface quality, to avoid collisions
between the tool and the tool holder
and to reduce the risk of long, oscillating tools [Wei05]. After production
has taken place, one of the forming
processes can be used to assemble the
frame components.
Dieless hydroforming: The process
of joining by dieless hydroforming
can be divided into three characteristic phases, which are indicated in
Fig. 2. In the first phase, the tube will
be expanded to some value within
the clearance (gap a0) limit. After
that, both parts (tube and hub) are
expanded together until a maximal radial displacement is reached, which is
determined by a related joining pressure. The pressure ideally creates
elastic and plastic deformation in the
tube but solely elastic deformation
in the hub. Consequently, Kollmann
[21] suggests that for the manufacturing of shrinkage fits a maximum
plastic deformation of approximately
30% should be attained, relative to
the total cross section of the joining
partner. After releasing the pressure,
both tube and hub recover elastically.
Subsequently, the elastic recovery of
the hub is prevented due to the plastic deformation remaining in the expanded tube.
Furthermore, the prevented elastic recovery of the hub results in an
interference fit between the joining
partners (tube and hub). It is known
from the manufacturing of camshafts
that if both joint partners possess
the same Young’s modulus then the
joining partners should be arranged
with increasing yield points from
the inner to the outer joining partner [22]. Joining of aluminium and
magnesium, as well as the influence
of maximum expansion under pressure, wall thickness of the hub, and
initial gap on the strength of the joint,
have been briefly presented in [23].
More detailed discussions take tools
and repeatability into account [24].
From an engineering standpoint, the
working parameter of the fluid pressure pf represents an important value
for estimating the resulting strength
of the joint. According to research
work performed by Garzke [22], the
interference pressure p, which is the
stress in the contact area of the tube
and hub, can be calculated using an
approximation.
Electromagnetic expansion: Electromagnetic forming (EMF) is a noncontact high velocity process using
pulsed magnetic fields to deform materials with high electrical conductivity, such as copper and aluminium alloys. Depending on arrangement and
geometry of the tool coil and the work
piece, EMF can be used for sheet metal forming operations or for compression or expansion of hollow profiles
[25]. Fig. 3 shows the typical set-up
of work piece, tool coil and forming
machine for the electromagnetic expansion of a square tube. This set-up
can be represented by a resonance
circuit in the equivalent circuit diagram. Within this diagram the forming
machine is symbolised by the capacitance C, the inner resistance Ri and
the inner inductance Li. The work
Fig. 3: Principle of the production of a square tube-to-hub joint by electromagnetic expansion
56
piece and the tool coil can be seen as
the consumer load. Due to a sudden
discharge of electricity from the capacitor, a damped sinusoidal current
I(t) runs through the coil. This current,
which typically ranges from 10 to
1,000 kA, generates a magnetic field
H(r,z,t) around the coil within several
microseconds. According to Lenz’s
law, this magnetic field induces eddy
currents in the work piece which are
in the opposite direction of the coil
current, and shield the magnetic field.
The energy density of the magnetic
field represents a pressure p(z,t) acting orthogonally on the workpiece
[25]. Plastic deformation of the tube
will occur once the stresses in the
work piece due to this pressure exceed the yield stress of the material.
A currently well investigated application of EMF in research is the
forming of sheet metal where the
work piece can either be deformed
freely or into a die to create a defined
shape. The process can also be used to
calibrate work pieces which were preformed by a conventional quasi-static
process [26] or for cutting/shearing
operations, but the most commonly
used industrial application of EMF is
the joining of closed hollow profiles.
By using electromagnetic compression
or expansion it is possible to produce
dominating interference-fit joints or
dominating form-fit joints [27]. In
the case of very high impact velocities of the electromagnetically driven
part it is possible to produce adhesive
bonds between the joining partners.
This application is called magnetic
pulse welding [28]. The strength of
the interference-fit depends on the
area of the contact zone, the friction
coefficient and the residual interference stresses in the contact zone. The
interference stresses are influenced
by the material properties of the
joining partners, such as yield stress
and Young’s modulus. The geometrical stiffness of the part to be joined
also affects the interference stresses
[29]. According to [30] and [31] the
strength of interference-fit joint produced by electromagnetic compression depends on the geometry and
the shape of the groove as well as on
the number of grooves. Both authors
ALUMINIUM · 3/2010
research
used cylindrical specimens for their
analyses.
analysis of joint characteristics
Strength of hydroformed joints: The
strength of the joint against an axial
load is mostlydependent on the area
of contact Acon, the interference pressure p, and the friction coefficient μ
between the two joining partners, as
indicated in equation (1)
Fax = Acon . µ . p
(1)
a wall thickness of 5 mm. Taking the
results of preliminary investigations
[33] into account an acceptable tangential strain of approximately 1.5%
was detected, and the gap a0 was set
to 0 mm. The pressure in phase 2 was
adjusted to 74 MPa, resulting in an expansion of 0.4 mm. After joining, an
axial load was applied using a tensile
test machine, and the results are displayed in Fig. 4.
At first, an increase of the average
surface roughness led to an increase
of the axial load. Tubes with a knurled
surface were significantly less resistant to deformation during tensile tests
compared to specimens with a milled
surface. As a result, the peaks created
by knurling the tube surface were too
large to generate an appropriate undercut with the opposite surface of
the hub. Moreover, a penetration of
the roughness peaks into the opposite
surface did not occur as the pressure
had already led to the maximum expansion. Using a die, an increase of
fluid pressure could lead to the mentioned penetration. Consequently, as
only the tips of knurling were in contact to the inner surface of the hub,
the area of contact was significantly
smaller compared to the machined
specimens. Since the area of contact
is directly proportional to the axial
load, the reduction in maximum axial
load is clearly evident.
Joining of square reinforced aluminium profiles by electromagnetic
expansion: Previous analysis regarding the strength of form-fit joints
considered primarily tubular specimens deformed by electromagnetic
compression [30, 31]. This work is
a first experimental approach to extend these analyses of form-fit joints
towards reinforced square tubes
produced by electromagnetic expansion. To generate the form-fit joints
a specified area of the tube was expanded into the grooves of the outer
joining partner, the hub (see Fig. 3).
The square tool coil used within these
experiments has an edge length of
40 mm and a length of 30 mm with
8 turns (E-40sqr-8/30). For this first
approach the groove width wg and
the groove length lg were kept constant. For wg a value of 20 mm was
chosen, which equals four times the
wall thickness of the profiles. For the
magnitude of lg the inner diameter of
the tubes was chosen (40 mm). The
height of the buckles h was varied by
changing the acting magnetic pressure and the charging energy E of
the capacitor bank. The maximum
height of the buckles was restricted
by the beginning of debonding at the
interface between the reinforcement
wire and aluminium matrix. During
the expansion of the tube the reinforcement wires are elongated. Due
to volume constancy an increasing
elongation leads to a decrease of
the cross section and, therefore, to
a separation of matrix material and
wires [29]. Debonding at the interface
disables or reduces load transmission
between matrix and wire, and therefore is not acceptable. To determine
the maximum allowable deformation and the corresponding charging
energy for the joining, a preliminary
test series was performed whereby
the profiles were expanded with
different charging energies within a
defined area and restricted by solid
collars. The distance between collars
was equivalent to the groove width
wg. The set-up of the preliminary
experiments is shown in Fig. 5. After the deformation the heights ➝
The area of contact Acon depends on
the length of the joint lj as well as the
interference diameter, and is directly
proportional to the resulting axial load
Fax. However, the interference pressure depends on the inner and outer
diameter of joining partners, material
characteristics as yield stress, Young’s
modulus, and Poisson‘s ratio, and the
maximum fluid pressure during joining. Joining of two tubes made from
the same material results in a low
maximum axial load [27]. As a result,
for an appropriate axial load to be
achieved, a modification of the coefficient of friction seems reasonable.
Therefore, adequate manufacturing
strategies, developed by the ISF, to
specifically adjust the roughness of
the tube have been applied and its
results on the strength of the joint
have been investigated. In addition
to the surface finishing by machining, burnishing was also applied as
a forming process for surface finishing. The mean roughnesses achieved
by the mentioned processes were
Ra = 0,63 μm by burnishing,
Ra = 3,4 μm to Ra = 7,5 μm by milling
[32] and Ra = 10 μm by turning. To
generate a disproportionately high
roughness a knurl pattern
was applied to the surface
by a milling process, so that
a calculated roughness of
Ra = 250 μm as found. Tubes
prepared so far were made
from aluminium EN AW-6060,
with an outer diameter of 40
mm and a wall thickness of 2
mm. They were joined with
ring-shaped hubs that had an
outer diameter of 50 mm and
Fig. 4: Axial load depending on the surface finish of joints made by dieless hydroforming
ALUMINIUM ·3/2010
57
research
Fig. 5: Top: Set-up and results of the preliminary tests for the expansion of reinforced
square tubes; bottom: Micrographs of the expanded tubes parallel to the wire
of the resulting buckles were measured with a coordinate-measuring
machine. The results show that an
increase in charging energy leads to
an increase in deformation.
In order to evaluate the quality
of the bonding between the aluminium matrix and the reinforcement
elements, micrographs of the electromagnetically formed specimens
were prepared, which also clearly
show the increasing deformation of
the tube with increasing charging energy. Charging energies of up to 1.6
kJ did not result in debonding at the
interface between the matrix material
and the wire. A further increase of the
charging energy led to debonding at
the interface, marked with arrows
in Fig. 5. Based on these preliminary
tests, a maximum charging energy
of 1.8 kJ was chosen for the joining
experiments. Although a very little
amount of debonding was observed
at this energy, it was assumed to have
no influence on the material strength.
To separate the influence of a pure
form-fit from the strength of the joint,
all specimens were lubricated with
Teflon grease before joining. As a result, the friction coefficient between
the joining partners was lowered to a
58
negligible level. Therefore, it was possible to nearly prevent an additional
interference-fit in the areas surrounding the grooves. After preparation the
specimens were expanded into the
grooves of the hub. Charging energies of 1.2 kJ, 1.4 kJ and 1.8 kJ were
used. Afterwards, pullout tests of the
joints were conducted using a universal tensile testing machine. The experimental results are shown in Fig. 6.
The diagram of the pullout force
F with respect to E indicates that a
higher charging energy and the resulting larger height of the buckles lead
to a higher strength of the joint. It can
also be seen that the strength of the
almost pure form-fit is very low compared to the material strength. This
can be explained by the small ratio of
the tube deformations compared to its
wall thickness, due to the debonding
restriction.
conclusion / Discussion
The necessity of a dedicated structuring of the surface of a joining zone is
undeniable. The use of simultaneous
five-axis milling strategies allow a reproducible structuring of the surface
of lightweight connecting elements in
order to control and increase tensile
and torsional strength of a joint. Interference-fit joining by expansion of
joining partners made from equal material results in a weak interference
pressure. As a result, the strength of
the joint determined by the area of
contact, interference pressure and
the coefficient of friction can be increased by modifying the surface
structure. Consequently, experimental investigations conducted so far
have confirmed the possibility of increasing the strength of the joint by
increasing the average surface roughness. However, there is a limit to the
increase in strength which can be
achieved by increasing the roughness.
The joining experiments of reinforced
square aluminium tubes by electromagnetic forming showed that an
increase in the height of the buckles
leads to an increase in the strength
of the joint. It was also shown that
the resulting joint strength was low
within these tests due to the small
allowable deformation. To achieve
reasonable strengths of the joints, a
combination of an interference-fit
and form-fit would be better. Also, an
optimisation of the form-fit might be
helpful to increase the transferable
load. In the case of non-reinforced
tubes it can be assumed that significantly higher joint strengths can be
achieved, since larger deformations
are feasible. Hence, the knowledge
of the interrelation between specific
surfaces and the resulting effects on
the quality of the joint allows the configuration of a flexible process chain
for machining and joining lightweight
frame structures.
conclusions
The presented innovative joining
methods allow for flexible manufacturing of lightweight frame structures
in limited-lot production. They enable
an economic production process and
lead to a lower structure weight.
Experiments show the weldability
of steel reinforced aluminium profiles by using friction stir welding.
This method is able to join the aluminium matrix material, but does not
connect the reinforcing elements. The
pre-treatment (sawing, milling) of the
ALUMINIUM · 3/2010
research
Joining by Compression and
Expansion of (Non-) Reinforced Profiles – In: Flexible
Manufacture of Lightweight
Frame Structures - Phase II:
Integration, Weinert, K. et al.
(eds.), TTP Trans Tech Publications Ltd, Switzerland,
Advanced Materials Research (2008) Vol. 43, ISBN
0-87849-385-9, pp. 57-68
[30]Golovashchenko,
S.:
“Methodology of Design
of Pulsed Electromagnetic
Joining of Tubes”, Proceedings of the TMS Symposium
“Innovations in Processing
and Manufacturing of Sheet
Materials”, 11-15 February
2001, New Orleans, Louisiana, pp. 283-299
Fig. 6: Results of the pullout tests of square reinforced tubes joined to square hubs
specimen has no significant influence
on the joint strength. The aluminium
alloy EN AW-6060, which is nearly impossible to fusion weld, can be joined
by using bifocal hybrid laser welding.
It could be shown that tube-tube-Ijoints can be produced with 93% of
the tensile strength of the tubes by
using an end crater reduction strategy. For modern joining by forming
processes an undeniable necessity for
dedicated structuring of the surface of
the joining zone exist. The knowledge
of the interrelation between specific
surfaces and the resulting effects on
the quality of the joint allows for the
configuration of a flexible process
chain for machining and joining lightweight frame structures.
acknowledgement
This paper is based on investigations
of the Transregional Collaborative
Research Centre SFB/TR10, which is
kindly supported by the German Research Foundation (DFG).
references
References from [1] to [19] are listed in
Part I of this paper, see ALUMINIUM 12/2010.
[20] Hammers, T.; Marré, M.; Rautenberg, J.; Barreiro, P.; Schulze, V.; Löhe,
D.; Brosius, A.; Tekkaya, E.: Influence of
mandrel’s surface on the mechanical properties of joints produced by electromagnetic compression. In: ICHSF 2008 – 3rd
International Conference on High Speed
Forming, 11/12 March 2008, Dortmund,
Germany, Proceedings, pp. 245-256, ISBN
ALUMINIUM ·3/2010
3-9809535-3-X
[21] Kollmann, F.: Welle-Nabe-Verbindungen, Gestaltung, Auslegung, Auswahl,
Springer Verlag Berlin (1984)
[22] Garzke, M.: Auslegung innenhochdruckgefügter Pressverbindungen unter
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Clausthal, VDI Verlag Düsseldorf, 2001
[23] Homberg, W.; Marré, M.; Beerwald,
C.; Kleiner, M.: Joining by forming of lightweight frame structures, In: Advanced
Materials Research: Flexible Manufacture
of Lightweight Frame Structures, Band 10
(2006), pp. 89-100
[24] Przybylski, W.; Wojciechowski, J.;
Marré, M.; Kleiner, M.: Influence of design
characteristics and manufacturing process
parameters on the strength of tubular aluminium joints produced by hydroforming. In: Archives of Mechanical Technology and Automation, Vol.27 Nr. 1, Polish
Academy of Science, 2007, pp. 152-167
ISSN 1233-9709
[25] Bruno, E. J.: High Velocity Forming of
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[26] Psyk, V.; Beerwald, C.; Henselek, A.;
Homberg, W.; Brosius, A.; Kleiner, M.: Integration of Electromagnetic Calibration into
the Deep Drawing Process of an Industrial
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Materials Vol. 344 (2007), pp. 435-442
[27] Marré, M.; Ruhstorfer, M.; Tekkaya,
A. E.; Zaeh; M. F.: Manufacturing of Lightweight Frame Structures by Innovative
Joining by Forming Processes. In: International Journal of Material Forming, 2009
– accepted
[28] Shribman, V.: Magnetic Pulse Welding for Dissimilar and Similar Materials.
In: ICHSF 2008 – 3rd International Conference on High Speed Forming, 11/12 March
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pp. 245 -256, ISBN 3-9809535-3-X
[29] Marré, M.; Brosius, A.; Tekkaya, A. E.:
[31]Bühler, H.; v. Finkenstein, E.: Bemessung von Sickenverbindungen für
ein Fügen durch Magnetumformung. In:
Werkstatt und Betrieb Vol. 104 (1971),
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[32]Biermann, D.; Weinert, K.; Zabel, A.;
Engbert, T.; Rautenberg, J.: Machining of
Lightweight Frame Components. In: Flexible Manufacture of Lightweight Frame
Structures – Phase II: Integration, Weinert,
K. et al. (eds.), TTP Trans Tech Publications Ltd, Switzerland, Advanced Materials Research (2008) Vol. 43, ISBN 0-87849385-9, pp. 37-46
[33] Hammers, T.; Marré, M.; Rautenberg,
J.; Barreiro, P.; Schulze, V.; Biermann, D.;
Brosius A.; Tekkaya, A. E.: Influence of
Mandrel’s Surface and Material on the
Mechanical Properties of Joints Produced
by Electromagnetic Compression. steel
research int., May Vol. 80 (2009) No. 5, S.
366-375; DOI: 10.2374/SRI08SP151
appendix
1
Technische Universität Dortmund
2
iwk I, Universität Karlsruhe (TH)
3
Technische Universität Dortmund
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Verfahren zur Herstellung einer Aero­
soldose aus Aluminium aus einem
Blechbund sowie Aerosoldose aus
Aluminium. Exal Corporation, Yongstown, OH 44502, US. (B21D 22/28, EPA
2119515, EP-AT: 27.06.2003)
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Gießkern zur Bildung eines Kühlkanals.
Mahle International GmbH, 70376 Stuttgart, DE. (B22C 9/10, OS 10 2008 020
231, AT: 22.04.2008)
Gerolltes Al­Mg­Si­Legierungsprodukt
mit guter Hemmung. Aleris Aluminium Duffel BVBA, 2570 Duffel, BE.
(B32B 15/01, EPA 2110235, EP-AT:
22.10.2008)
Verbindung zwischen einem Rohrprofil
aus Stahl und einem Bauteil aus Alumi­
nium. Benteler Automobiltechnik GmbH,
33102 Paderborn, DE. (B23K 20/16, PS
10 2008 037 709, AT: 14.08.2008)
Kolben für einen Verbrennungsmotor.
Mahle International GmbH, 70376 Stuttgart, DE. (F16J 1/16, EPA 2094997, EPAT: 23.10.2007)
Glänzende Beschichtungen für Alumi­
nium­ oder Stahlkraftfahrzeugrädern
und deren Herstellung. Daimler AG,
70327 Stuttgart, DE. (C23K 14/06, EPA
L12­Aluminiumlegierungen.
United
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Zweiteiliger Kolben für einen Ver­
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60
Produkt aus einer Al­Mg­Legierung für
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ALUMINIUM · 3/2010
PAt e N t e
Wärmebehandlungsfähige L12­Alumi­
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21/06, C22C 21/10 u. C22C 21/16, EPA
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Hochfeste L12­Aluminiumlegierungen.
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Anodische Oxidschicht für elektrische
Leiter, insbesondere Leiter aus Alumi­
nium, Verfahren zur Erzeugung einer
anodischen Oxidschicht und elektri­
scher Leiter mit anodischer Oxidschicht.
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Al­Si­Legierung mit reduzierter Nei­
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Verfahren zur Herstellung eines Blechs
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produkten, sog. Masseln, zu Trans­
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Verfahren zur Herstellung eines Bau­
teils aus einer Aluminiumlegierung
durch Druckgießen. BDW technologies
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(C22F 1/043, PS 599 03 009, EP 0997550,
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Gegenstand mit einem Flächenelement
aus Aluminium. Sommer GmbH, 71691
Freiberg, DE. (B41M 1/28, GM 20 2006
014 584, AT: 20.09.2006)
Hitzebeständige und hochzähe Alumi­
niumlegierung und Herstellungsver­
fahren dafür und Motorenteile. Honda
Motor Co., Ltd., Tokyo, JP; Sumitomo
Electric Sintered Alloy, Ltd., Okayama,
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Aluminium (Schreinerschieblehre). Simmat, Rainer, 33790 Halle, DE. (G01B 3/20,
GM 20 2009 004 466, AT: 31.03.2009)
Aluminiumgleitlagerlegierung. Deutsches Zentrum für Luft- und Raumfahrt
e.V., 51147 Köln, DE; Technische Universität Clausthal, 38678 Clausthal-Zellerfeld, DE. (C22C 21/00, PS 50 2005 006
241, EP 1888798, EP-AT: 07.06.2005)
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Rührkörpern zum Umschmelzen von
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Aluminiumkolben, der zumindest teil­
weise mit einem Aluminiumoxidfilm
bedeckt ist. Aisin Seiki K.K., Kariya, Aichi, JP. (C25D 1/00, PS 60 2005 011 738,
EP 1657326, EP-AT: 15.11.2005)
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Automobiltechnik GmbH, 33102 Paderborn, DE. (F28F 21/08, PS 10 2007 015
146, AT: 29.03.2007)
Elektrischer Draht mit Aluminium­ oder
Aluminiumlegierungskern. Nexans, Paris, FR. (C25D 7/06, EP 1 700 933, EP-AT:
03.02.2006
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tensystem und Verfahren zur Herstel­
lung des Gerüstbodens. UTI Holding +
Management AG, 60487 Frankfurt, DE.
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Ultraleichte und parfümierte Kompasse
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EPA 2116392, EP-AT: 05.06.2008)
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Herstellen des Verbundwerkstoffs
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me, ihre Verwendung und Verfahren
zur Herstellung. Helmholtz-Zentrum
Berlin für Materialien und Energie
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OS 10 2008 027 798, AT: 11.06.2008)
Folie aus Aluminiumlegierung und Ver­
fahren zu deren Herstellung. Novelis
Inc., Toronto, Ontario, CA. (C22C 21/02,
PS 60 2006 004 594, EP 1902149, EP-AT:
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aus einer Aluminiumlegierung. Alcoa
Inc., Pittsburgh, Pa., US. (C22F 1/057,
PS 691 25 436, EP 0473122, EP-AT:
27.08.1991)
Zähe Aluminiumlegierung mit Kupfer
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Aluminiumlegierung für Verkehrsflug­
zeugflügel. Alcoa Inc., Alcoa Center, Pa.,
US. (C22F 1/04, PS 696 29 113, 0829552,
EP-AT: 11.09.1996)
Verfahren zum Herstellen von Zylin­
derblöcken aus Leichtmetall mit einge­
schweißten Leichtmetall­Zylinderbüch­
sen und Einrichtung zur Durchführung
des Verfahrens. Volkswagen AG, 38440
Wolfsburg, DE. (B23P 13/00, PS 100 19
783, AT: 20.04.2000)
Schleuderstrahlanlage zum Strahlen
von Werkstücken aus Leichtmetallle­
gierungen. Disa Industrie AG, Schaffhausen, CH. (B24C 3/18, PS 50 2005 006
059, EP 1714742, EP-AT: 21.04.2005)
Magnesiumlegierung. Stolfig, Peter,
85290 Geisenfeld, DE. (C22C 23/00, GM
202 02 591, AT: 20.02.2002)
Verfahren zur Herstellung eines Bau­
materials aus magnesiumhaltiger Le­
gierung auf Aluminiumbasis. Advanced
Alloys SA, 1201 Genéve, CH. (C22C 1/02,
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61
PAt e N t e
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Kriechbeständige
Magnesiumlegie­
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AG, 38440 Wolfsburg, DE. (C22C 23/06,
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Legierungen der Serie 2000 mit Scha­
denstoleranzleistung für Luft­ und
Raumfahrtanwendungen. Alcoa Inc.,
Pittsburgh, Pa., US. (C22C 21/00, GM 20
2006 020 514, AT: 07.09.2006)
Korrosionsbeständige
Legierungen
der 6000­Serien, verwendbar für die
Luftfahrt. Alcoa Inc., Pittsburgh, Pa., US.
(C22C 21/08, PS 601 08 382, EP 1290235,
EP-AT: 01.06.2001)
Fahrzeugrahmenbauteile mit verbes­
serter
Energieabsorptionsfähigkeit,
Verfahren zu ihrer Herstellung und
eine Legierung. Alcoa Inc., Pittsburgh,
Pa., US. (C22C 21/08, PS 696 33 002, EP
0805219, EP-AT: 03.05.1996)
Verbundmetalltafel und Herstellungs­
verfahren dafür. Alcan Rhenalu, 92400
Courbevoie, FR. (E04C 2/34, EPA
2115233, WO 2008/113911, EP-AT:
08.02.2008, WO-AT: 08.02.2008
Deckfolie für Blisterverpackungen.
Alcan Technology & Management Ltd.,
8212 Neuhausen am Rheinfall, CH.
(B65D 75/34, EPA 2112090, EP-AT:
22.04.2008)
Verpackungsdeckfolie, Behältnis, Ver­
packung und Verpackungsproduktein­
heit. Alcan Technology & Management
AG, Neuhausen am Rheinfall, CH.
(B65D 65/40, OS 10 2008 023 952, AT:
16.05.2008)
Aluminiumlegierungsstreifen
zum
Schweißen. Alcan Rhenalu, Paris, FR;
Alcan Rolled Products Ravenswood LLC,
Ravenswood, W.Va., US. (B23K 1/00, PS
60 2004 018 970, EP 1687115, EP-AT:
24.11.2004)
Verfahren zur Herstellung hochfester
und ermüdungsfester Aluminiumlegie­
rungsprodukte. Alcan Rhenalu, Paris,
FR. (C22F 1/053, PS 60 2005 011 619,
EP 1766102, EP-AT: 22.06.2005)
Fenster, Fenstertür oder dergleichen
mit einem belüfteten Rahmen, mit
Fluidverbindungsmitteln von einer
Luftschicht zur Außenumgebung über
eine Profildichtung im unteren Quer­
träger der Außenglasscheibe. Norsk
62
Hydro ASA, Oslo, NO. (E06B 3/673, EP
1 700 992, EP-AT: 09.03.2006)
Anlage und Verfahren zur Verarbei­
tung linear geschmolzener Metalle
mithilfe eines Salzreaktants in einem
Tiefbettentgaser. Alcoa Inc., Pittsburgh,
PA 15069-0001, US. (C22B 9/10, EPA
2113033, WO 2008/103912, EP-AT:
22.02.2008, WO-AT: 22.02.2008)
System zur Zufuhr von Metallschmelze
unter konstantem Druck und Verfah­
ren zur Herstellung von Endlosmetall­
artikeln. Alcoa Inc., Pittsburgh, Pa., US.
(B22D 11/00, PS 602 13 977, EP 1395380,
EP-AT: 18.04.2002)
Fahrzeugrahmenbauteile mit verbes­
serter
Energieabsorptionsfähigkeit,
Verfahren zu ihrer Herstellung und
eine Legierung. Alcoa Inc., Pittsburgh,
Pa., US. (C22C 21/08, PS 696 33 002, EP
0805219, EP-AT: 03.05.1996)
eines Luftspaltes mit der Außenumge­
bung durch eine Außenglasscheibe
und eine diese Scheibe haltende Lei­
ste. Norsk Hydro ASA, Oslo, NO. (E06B
3/673, EP 1 700 993, EP-AT: 09.03.2006)
Koaxialprofil und Verfahren zur Her­
stellung eines solchen Koaxialprofils.
Erbslöh Aluminium GmbH, 42553 Velbert, DE. (F16L 9/18, F28D 7/10, PS
10 2008 022 933, EPA 2116803, AT:
09.05.2008, EP-AT: 05.05.2009)
Gebäudefassade oder Dachfassade
mit Ausfachungen. Hermann Gutmann
Werke AG, 91781 Weissenburg, DE. (E04B
2/96, OS 10 2008 022 650, EPA 2116659,
AT: 07.05.2008,EP-AT: 04.04.2009)
Fensterkonstruktion, insb. Dachfens­
terkonstruktion. Hermann Gutmann
Werke AG, 91781 Weißenburg, DE.
(E06B 3/30, GM 20 2006 014 581, AT:
20.09.2006
Kühlungssystem für eine Bandstrang­
gießanlage und damit zusammenhän­
gende Verfahren. Alcoa Inc., Pittsburgh,
Pa., US. (B22D 11/06, PS 697 15 371, EP
0873211, EP-AT: 08.01.1997)
Kolben für einen Verbrennungsmotor
und Verfahren zu seiner Herstellung.
Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/16, OS 10 2008 028 197,
AT: 12.06.2008)
Gegossene Rahmenelemente für Kraft­
fahrzeuge. Alcoa Inc., Pittsburgh, Pa., US.
(B62D 29/00, PS 699 12 795, EP 1100714,
EP-AT: 02.08.1999)
Verfahren und Vorrichtung zur Erhö­
hung der Wärmebeständigkeit und
der Alterungsstabilität von Alumi­
niumblechen und hergestellte Pro­
dukte. Reynolds Metals Co., Richmond,
Va., US. (C21D 9/46, PS 696 28 044, EP
0874917, EP-AT: 17.12.1996, WO-AT:
17.12.1996)
Längliches Halteelement. Corus Bausysteme GmbH, 56070 Koblenz, DE. (E04D
3/362, GM 203 80 217, AT: 29.08.2003)
Tür, Fenster oder dergleichen in wärme­
gedämmter Ausführung. Norsk Hydro
ASA, 0257 Oslo 2, NO. (E06B 3/263, EPA
2116685, EP-AT: 25.04.2009)
Ausfachungsrahmen für Gebäudefas­
saden. Hydro Aluminium AS, Oslo, NO.
(E04B 2/96, OS 10 2008 030 786, AT:
28.06.2008)
Druckplattenträger und Verfahren zur
Herstellung eines Druckplattenträgers
oder einer Offsetdruckplatte. Hydro
Aluminium Deutschland GmbH, 51149
Köln, DE. (B41N 1/08, PS 199 02 527,
AT: 22.01.1999)
Verfahren zur Herstellung eines Be­
hälters aus Aluminiumblechen. Hydro
Aluminium Deutschland GmbH, 51149
Köln, DE. (B21D 51/24, EP 2 026 920,
WO 2007/141217, EP-AT: 01.06.2007,
WO-AT: 01.06.2007)
Wetterschutzschiene sowie Tür bzw.
Fenster. Hermann Gutmann Werke AG,
91781 Weißenburg, DE. (E06B 1/34, GM
20 2008 008 486, AT: 26.06.2008)
Belüftetes Fenster, Fenstertür oder
dergleichen, mit einer Fluidverbindung
Verfahren zur Herstellung von Alumi­
niummaterial für eine Elektrode eines
elektrolytischen Kondensators. Showa Denko K.K., Tokio/Tokyo, JP. (C22F
1/04, PS 603 29 004, EP 1541704, EP-AT:
25.06.2003, WO-AT: 25.06.2003)
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),
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D-06112 Halle an der Saale,
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Fax 0345/29398-40,
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Die Gesellschaft bietet darüber hinaus
weitere Patent-Dienstleistungen an.
ALUMINIUM · 3/2010
International Journal for Industry, Research and Application
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Lieferverzeichnis
1 Smelting technology
Hüttentechnik
1.1 Raw materials
1.2 Storage facilities for smelting
1.3 Anode production
1.4 Anode rodding
1.4.1 Anode baking
1.4.2 Anode clearing
1.4.3 Fixing of new anodes to the anodes bars
1.5 Casthouse (foundry)
1.6 Casting machines
1.7 Current supply
1.8 Electrolysis cell (pot)
1.9 Potroom
1.10 Laboratory
1.11 Emptying the cathode shell
1.12 Cathode repair shop
1.13 Second-hand plant
1.14 Aluminium alloys
1.15 Storage and transport
1.16 Smelting manufactures
1.1 Raw Materials/Rohstoffe
 Raw Materials / Rohstoffe
1.1 Rohstoffe
1.2 Lagermöglichkeiten in der Hütte
1.3 Anodenherstellung
1.4 Anodenschlägerei
1.4.1 Anodenbrennen
1.4.2 Anodenschlägerei
1.4.3 Befestigen von neuen Anoden an der -stange
1.5 Gießerei
1.6 Gießmaschinen
1.7 Stromversorgung
1.8 Elektrolyseofen
1.9 Elektrolysehalle
1.10 Labor
1.11 Ofenwannenentleeren
1.12 Kathodenreparaturwerkstatt
1.13 Gebrauchtanlagen
1.14 Aluminiumlegierungen
1.15 Lager und Transport
1.16 Hüttenerzeugnisse
 Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
 Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
FLSmidth MöLLer GmbH
Internet: www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
TrIMeT ALuMInIuM AG
Aluminiumallee 1
D-45356 Essen
Tel.: +49 (0) 201 / 3660
Fax: +49 (0) 201 / 366506
E-Mail: info@trimet.de
Internet: www.trimet.de
1.2 Storage facilities for
smelting
 Exhaust gas treatment
Abgasbehandlung
Solios Carbone – France
www.solios.com
 Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
FLSmidth MöLLer GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
 Mixing Technology for
Anode pastes
Lagermöglichkeiten i.d. Hütte
FLSmidth MöLLer GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
E-Mail: moeller@flsmidth.com
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
LAeIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone: +352 27612 0
Fax: +352 27612 109
E-Mail: info@laeis-gmbh.com
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
ALuMInA And peT COke SHIpunLOAderS
Contact: Andreas Haeuser, ha@neuero.de
Mischtechnologie für Anodenmassen
1.3 Anode production
Anodenherstellung
Buss AG
CH-4133 Pratteln
Phone:
+41 61 825 66 00
E-Mail:
info@busscorp.com
Internet: www.busscorp.com
see Storage facilities for smelting 1.2
Outotec GmbH
Albin-Köbis-Str. 8, D-51147 Köln
Phone: +49 (0) 2203 / 9921-0
E-mail: aluminium@outotec.com
www.outotec.com
Solios Carbone – France
www.solios.com
 Auto firing systems
 Open top and closed
type baking furnaces
rIedHAMMer GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: frank.goede@riedhammer.de
Internet: www.riedhammer.de
rIedHAMMer GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: frank.goede@riedhammer.de
Internet: www.riedhammer.de
Automatische Feuerungssysteme
Offene und geschlossene Ringöfen
 Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: info.cc-mh@coperion.com
64
ALUMINIUM · 3/2010
Lieferverzeichnis
1.4 Anode rodding
Anodenanschlägerei
1.4.3 Fixing of new anodes
to the anodes bars
Befestigen von neuen
Anoden a. d. Anodenstange
 Fixing the nipples to the
anodes by casting in
see Storage facilities for smelting 1.2
 Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
Befestigen der Nippel mit der
Anode durch Eingießen
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
see Casting Machines 1.6
1.5 Casthouse (foundry)
Gießerei
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
E-Mail: sales@mechatherm.com
www.mechatherm.com
 Transport of finished anode
elements to the pot room
1.4.1 Anode baking
Anodenbrennen
Entgasung, Filtern, Kornfeinung
drache umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
engineering GmbH
see Casting equipment 3.1
 Dross skimming of liquid metal
Abkrätzen des Flüssigmetalls
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Dross skimming of the melt
Abkrätzen der Schmelze
E-Mail: sermas@sermas.com
see Casting machines 1.6
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 info@windhoff.de
Internet www.windhoff.de
 Degassing, filtration and
grain refinement
HerTWICH enGIneerInG GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
E-Mail: info@inotherm-gmbh.de
Internet: www.inotherm-gmbh.de
 Anode charging
 Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
Solios Carbone – France
www.solios.com
Anodenchargieren
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
see Casting Machines 1.6
 Anode storage
Anodenlager
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
see Casting Machines 1.6
see Equipment and accessories 3.1
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
E-Mail: interstop@stopinc.ch
Internet: www.stopinc.ch
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Clay / Tonerde
1.4.2 Anode clearing
Anodenschlägerei
 Separation of spent anodes
from the anode bars
Trennen von den Anodenstangen
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
see Casting Machines 1.6
ALUMINIUM · 3/2010
TrIMeT ALuMInIuM AG
Aluminiumallee 1
D-45356 Essen
Tel.: +49 (0) 201 / 3660
Fax: +49 (0) 201 / 366506
E-Mail: info@trimet.de
Internet: www.trimet.de
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y.Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
E-Mail: info@sistemteknik.com
Internet: www.sistemteknik.com
65
Lieferverzeichnis
 Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Transfer to the casting furnace
 Rolling and extrusion ingot
and T-bars
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
engineering GmbH
see Casting equipment 3.1
 Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
engineering GmbH
see Casting equipment 3.1
Überführung in Gießofen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
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
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
Gautschi
engineering GmbH
see Casting equipment 3.1
Horizontales Stranggießen
Gautschi
engineering GmbH
see Casting equipment 3.1
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Horizontal continuous casting
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
see Billet Heating Furnaces 1.5
 Vertical semi-continuous DC
casting / Vertikales Stranggießen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
MArx GmbH & Co. kG
www.marx-gmbh.de
see Melt operations 4.13
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Scales / Waagen
Gautschi
engineering GmbH
see Casting equipment 3.1
1.8 Electrolysis cell (pot)
 Treatment of casthouse
off gases
Elektrolyseofen
Behandlung der Gießereiabgase
Gautschi
engineering GmbH
see Casting equipment 3.1
Solios Carbone – France
www.solios.com
1.6 Casting machines
Gießmaschinen
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
E-Mail: info@wagstaff.com
Internet: www.wagstaff.com
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Sawing / Sägen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: info.cc-mh@coperion.com
 Calcium silicate boards
Calciumsilikatplatten
promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
verkauf3@promat.de, www.promat.de
www.mechatherm.com
see Smelting technology 1.5
 Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Gautschi
engineering GmbH
see Casting equipment 3.1
see Storage facilities for smelting 1.2
66
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Exhaust gas treatment
Abgasbehandlung
Solios Carbone – France
www.solios.com
343 Chemin du Stade
38210 Saint Quentin sur Isère
Tel. +33 (0) 476 074 242
Fax +33 (0) 476 936 776
E-Mail: sermas@sermas.com
Internet: www.sermas.com
 Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
FLSmidth MöLLer GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
ALUMINIUM · 3/2010
Lieferverzeichnis
1.9 Potroom
Elektrolysehalle
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
E-Mail: gmagarotto@tomorrowtechnology.it
Contact: Giovanni Magarotto
 Anode changing machine
Anodenwechselmaschine
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 HF Measurementtechnology
HF Messtechnik
OpSIS AB
Box 244, S-24402 Furulund, Schweden
Tel. +46 (0) 46-72 25 00, Fax -72 25 01
E-Mail: info@opsis.se
Internet: www.opsis.se
 Tapping vehicles/Schöpffahrzeuge
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Ofenwannenentleeren
 Cathode bar casting units
Kathodenbarreneingießanlage
E-Mail: sermas@sermas.com
see Casting machines 1.6
1.14 Aluminium Alloys
Aluminiumlegierungen
 Crustbreakers / Krustenbrecher
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Carbone – France
www.solios.com
2
Lager und Transport
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
1.11 Emptying the cathode shell
 Anode transport equipment
Anoden Transporteinrichtungen
1.15 Storage and transport
rHeInFeLden ALLOYS GmbH & Co. kG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
E-Mail: alloys@rheinfelden-alloys.eu
Internet: www.rheinfelden-alloys.eu
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Beate Schaefer, Tel: 0511 7304-148
1.16 Smelting manufactories
Hüttenerzeugnisse
 Rolling ingots
Walzbarren
Alcan Aluminium Valais SA
CH-3960 Sierre
Telefon: 0041 27 / 4575111
Telefax: 0041 27 / 4576425
Extrusion
Strangpressen
2.1 Extrusion billet preparation
2.1.1 Extrusion billet production
2.2 Extrusion equipment
2.3 Section handling
2.4 Heat treatment
2.5 Measurement and control equipment
2.6 Die preparation and care
2.7 Second-hand extrusion plant
2.8 Consultancy, expert opinion
2.9 Surface finishing of sections
2.10 Machining of sections
2.11 Equipment and accessories
2.12 Services
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
www.mechatherm.com
see Smelting technology 1.5
www.alu-web.de
ALUMINIUM · 3/2010
2.1 Pressbolzenbereitstellung
2.1.1 Pressbolzenherstellung
2.2 Strangpresseinrichtungen
2.3 Profilhandling
2.4 Wärmebehandlung
2.5 Mess- und Regeleinrichtungen
2.6 Werkzeugbereitstellung und -pflege
2.7 Gebrauchte Strangpressanlagen
2.8 Beratung, Gutachten
2.9 Oberflächenveredlung von Profilen
2.10 Profilbearbeitung
2.11 Ausrüstungen und Hilfsmittel
2.12 Dienstleistungen
 Billet heating furnaces
Öfen zur Bolzenerwärmung
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de
MArx GmbH & Co. kG
www.marx-gmbh.de
see Melt operations 4.13
67
Lieferverzeichnis
 Containers / Rezipienten
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y. Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
E-Mail: info@sistemteknik.com
Internet: www.sistemteknik.com
2.1.1 Extrusion billet
production
SMS Meer GmbH
see Extrusion equipment 2.2
Vollert Anlagenbau
GmbH + Co. kG
Stadtseestraße 12
D-74189 Weinsberg
Tel.
+49 (0) 7134 / 52-220
Fax
+49 (0) 7134 / 52-222
E-Mail intralogistik@vollert.de
Internet www.vollert.de
 Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
 Puller equipment
SMS Meer GmbH
see Extrusion equipment 2.2
SMS Meer GmbH
see Extrusion equipment 2.2
see Extrusion Equipment 2.2
Ausziehvorrichtungen/Puller
Pressbolzenherstellung
www.mechatherm.com
see Smelting technology 1.5
 Billet transport and storage
equipment
Bolzen-Transport- u. Lagereinricht.
 Temperature measurement
Temperaturmessung
 Section cooling
Profilkühlung
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
See Casting Machines 1.6
SMS Meer GmbH
see Extrusion equipment 2.2
2.2 Extrusion equipment
Strangpresseinrichtungen
 Heating and control
equipment for intelligent
billet containers
SMS Meer GmbH
see Extrusion equipment 2.2
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
 Section saws
www.mechatherm.com
see Smelting technology 1.5
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
E-Mail: info@oilgear.de
Internet: www.oilgear.de
Profilsägen
MArx GmbH & Co. kG
www.marx-gmbh.de
see Melt operations 4.13
SMS Meer GmbH
see Extrusion equipment 2.2
2.3 Section handling
Profilhandling
 Packaging equipment
Verpackungseinrichtungen
SMS Meer GmbH
Schloemann Extrusion
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Tel. +49 (0) 2161 350-0
Fax +49 (0) 2161 350-1667
E-Mail: info@sms-meer.com
Internet: www.sms-meer.com
68
H+H HerrMAnn + HIeBer GMBH
Fördersysteme für paletten
und schwere Lasten
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
 Section store equipment
Profil-Lagereinrichtungen
H+H HerrMAnn + HIeBer GMBH
Fördersysteme für paletten
und schwere Lasten
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
ALUMINIUM · 3/2010
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
kasto@kasto.de / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
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: info@herrmannhieber.de
Internet: www.herrmannhieber.de
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
 Section transport equipment
 Heat treatment furnaces
Wärmebehandlungsöfen
ELPO GmbH
Kuchengrund 18
71522 Backnang
Telefon 07191 9572-0
Telefax 07191 9572-29
E-Mail: info@elpo.de
Internet: www.elpo.de
InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH
see Casthouse (foundry) 1.5
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
Profiltransporteinrichtungen
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Beate Schaefer, Tel: 0511 7304-148
SMS Meer GmbH
see Extrusion equipment 2.2
2.4 Heat treatment
Wärmebehandlung
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
 Stackers / Destackers
Stapler / Entstapler
see Billet Heating Furnaces 2.1
 Custom designed heat
processing equipment
Kundenspezifische
Wärmebehandlungsanlagen
Sistem Teknik Ltd. Sti.
see Billet Heating Furnaces 2.1
 Homogenising furnaces
Homogenisieröfen
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
info@bsn-therm.de · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
www.mechatherm.com
see Smelting technology 1.5
SMS Meer GmbH
see Extrusion equipment 2.2
 Stretching equipment
Reckeinrichtungen
SeCO/WArWICk S.A.
Sobieskiego 8, 66-200 Swiebodzin PL
tel./fax +48 68 4111 600 (655)
Fax +49 (0) 711 / 3 46 0911
info@secowarwick.com.pl
www.secowarwick.com.pl
SeCO/WArWICk S.A.
see Heat treatment 2.4
 Annealing furnaces
Glühöfen
SMS Meer GmbH
see Extrusion equipment 2.2
ALUMINIUM · 3/2010
see Equipment and accessories 3.1
see Billet Heating Furnaces 2.1
69
Lieferverzeichnis
2.5 Measurement and
control equipment
2.7 Second-hand
extrusion plant
2.11 Equipment and
accessories
 Extrusion plant control systems
Qualiteam International/extruprex
Champs Elyséesweg 17, NL-6213 AA Maastricht
Tel. +31-43-3 25 67 77
Internet: www.extruprex.com
 Inductiv heating equipment
Mess- und Regeleinrichtungen
Presswerkssteuerungen
Gebr. Strangpressanlagen
Ausrüstungen und
Hilfsmittel
Induktiv beheizte
Erwärmungseinrichtungen
2.8 Consultancy,
expert opinion
SMS Meer GmbH
see Extrusion equipment 2.2
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
Beratung, Gutachten
Dr.-Ing. Alexander Klaus, zert. Master Blackbelt
Konrad-Adenauer-Str. 12, D-76877 Offenbach
Tel.: +49 6348 247 67-0, Fax: 247 67-1
E-Mail: mail@klausleansigma.de
Internet: www.klausleansigma.de
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de
 Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
 Die heating furnaces
Werkzeuganwärmöfen
MArx GmbH & Co. kG
www.marx-gmbh.de
see Melt operations 4.13
do you need
more
information?
E-Mail:
anzeigen@giesel.de
2.10 Machining of sections
Sistem Teknik Ltd. Sti.
see Billet Heating Furnaces 2.1
Profilbearbeitung
see Billet Heating Furnaces 2.1
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
 Processing of Profiles
Profilbearbeitung
2.12 Services
Dienstleistungen
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Tensai (International) AG
extal division
Steinengraben 40
CH-4051 Basel
Telefon +41 (0) 61 284 98 10
Telefax +41 (0) 61 284 98 20
E-Mail: tensai@tensai.com
 Process improvement and
cost reduction
Prozessoptimierung und Kostensenkung
Klaus LeanSigma
Technologie & Ci für die Aluminiumindustrie
see Consultancy, expert opinion 2.8
Could not find your „keywords“?
please ask for our complete
„Supply sources for the aluminium industry“.
e-Mail: anzeigen@giesel.de
70
ALUMINIUM · 3/2010
Lieferverzeichnis
3 Rolling mill technology
Walzwerktechnik
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
3.18
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
Productions Management Systems
3.0 Rolling mill technology
Walzwerktechnik
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
3.18
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
Produktions Management Systeme
 Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Carbone – France
www.solios.com
 Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
engineering GmbH
see Casting equipment 3.1
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
E-Mail: communications@sms-siemag.com
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
elektrik + Automation
Ivo-Beucker-Straße 43
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
40239 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Wagstaff, Inc.
Solios Carbone – France
www.solios.com
 Melt purification units
Schmelzereinigungsanlagen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Metal filters / Metallfilter
Gautschi
engineering GmbH
see Casting equipment 3.1
see Casting machines 1.6
 Melting and holding furnaces
Schmelz- und Warmhalteöfen
Gautschi
engineering GmbH
Geschäftsbereich Aluminium
Konstanzer Straße 37
Postfach 170
CH 8274 Tägerwilen
Telefon +41/71/6666666
Telefax +41/71/6666688
E-Mail: aluminium@gautschi-engineering.com
Kontakt: Stefan Blum, Tel. +41/71/6666621
 Metal pumps / Metallpumpen
Solios Carbone – France
www.solios.com
3.2 Rolling bar machining
Walzbarrenbearbeitung
 Band saws / Bandsägen
SMS Meer GmbH
see Extrusion equipment 2.2
3.1 Casting equipment
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
E-Mail: info@loi-italimpianti.de
Internet: www.loi-italimpianti.com
www.mechatherm.com
see Smelting technology 1.5
SeCO/WArWICk S.A.
see Heat treatment 2.4
SMS Meer GmbH
see Extrusion equipment 2.2
 Slab milling machines
Barrenfräsmaschinen
Gießanlagen
ALUMINIUM · 3/2010
71
Lieferverzeichnis
3.3 Rolling bar furnaces
 Roller tracks
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
Gautschi
engineering GmbH
see Casting equipment 3.1
Walzbarrenvorbereitung
Rollengänge
 Annealing furnaces
Glühöfen
3.4 Hot rolling equipment
 Spools / Haspel
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Warmwalzanlagen
eBner Industrieofenbau Ges.m.b.H.
Ruflinger Str. 111, A-4060 Leonding
Tel. +43 / 732 / 68 68
Fax +43 / 732 / 68 68-1000
Internet: www.ebner.cc
E-Mail: sales@ebner.cc
Gautschi
engineering GmbH
see Casting equipment 3.1
 Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
see Equipment and accessories 3.1
schwartz GmbH
see Heat treatment 2.4
Solios Carbone – France
www.solios.com
 Bar heating furnaces
Barrenanwärmanlagen
eBner Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
engineering GmbH
see Casting equipment 3.1
 Homogenising furnaces
Homogenisieröfen
Gautschi
engineering GmbH
see Casting equipment 3.1
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
www.alu-web.de
72
3.5 Strip casting units
and accessories
Bandgießanlagen und
Zubehör
 Cores & shells for continuous
casting lines
 Coil transport systems
Bundtransportsysteme
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
 Drive systems / Antriebe
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Cores & shells 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: aluminium.dept@brunopresezzi.com
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
 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: aluminium.dept@brunopresezzi.com
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
 Rolling mill modernisation
 Twin-roll continuous casting
lines (complete lines)
SMS Siemag 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: aluminium.dept@brunopresezzi.com
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
Walzwerksmodernisierung
Solios Carbone – France
www.solios.com
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Twin-roll continuous casting lines
(complete lines)
ALUMINIUM · 3/2010
Lieferverzeichnis
3.6 Cold rolling equipment
Kaltwalzanlagen
 Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
 Process optimisation systems
Prozessoptimierungssysteme
Gautschi
engineering GmbH
see Casting equipment 3.1
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
 Process simulation
Prozesssimulation
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
 Coil annealing furnaces
Bundglühöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Drive systems / Antriebe
Gautschi
engineering GmbH
see Casting equipment 3.1
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
 Revamps, equipments & spare parts
see Equipment and accessories 3.1
Revamps, equipments & spare parts
 Heating furnaces / Anwärmöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
Bruno presezzi SpA
Via per Ornago 8
I-20040 Burago Molgora (Mi) – Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
 Roll exchange equipment
Walzenwechseleinrichtungen
SeCO/WArWICk S.A.
see Heat treatment 2.4
Hier könnte Ihr
 Coil transport systems
Bundtransportsysteme
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
ALUMINIUM · 3/2010
BezugsquellenEintrag
stehen.
Rufen Sie an:
Tel. 0511 / 73 04-148
Beate Schaefer
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
73
Lieferverzeichnis
 Rolling mill modernization
Walzwerkmodernisierung
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
 Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
see Cold rolling units / complete plants 3.6
see Cold rolling units / complete plants 3.6
Revamps, equipments & spare parts
 Slitting lines-CTL
Längs- und Querteilanlagen
 Coil annealing furnaces
see Cold rolling units / complete plants 3.6
Bundglühöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
 Strip shears
Bruno presezzi SpA
Via per Ornago 8
I-20040 Burago Molgora (Mi) – Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.brunopresezzi.com
Contact: Franco Gramaglia
 Rolling mill modernization
Bandscheren
see Cold rolling units / complete plants 3.6
 Revamps, equipments
& spare parts
Walzwerkmodernisierung
see Equipment and accessories 3.1
schwartz GmbH
see Cold colling equipment 3.6
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
3.9 Adjustment devices
SeCO/WArWICk S.A.
see Heat treatment 2.4
Adjustageeinrichtungen
 Sheet and plate stretchers
Blech- und Plattenstrecker
 Trimming equipment
Besäumeinrichtungen
see Cold rolling units / complete plants 3.6
 Heating furnaces
Anwärmöfen
Gautschi
engineering GmbH
see Casting equipment 3.1
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
www.alu-web.de
74
InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH
see Casthouse (foundry) 1.5
SMS Meer GmbH
see Extrusion equipment 2.2
 Cable sheathing presses
Kabelummantelungspressen
SMS Meer GmbH
see Extrusion equipment 2.2
ALUMINIUM · 3/2010
Lieferverzeichnis
 Cable undulating machines
Kabelwellmaschinen
 Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
SMS Meer GmbH
see Extrusion equipment 2.2
 Transverse cutting units
Querteilanlagen
ABB Automation Technologies AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
See Casting Machines 1.6
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
3.11 Coolant / lubricant
preparation
Kühl-/SchmiermittelAufbereitung
 Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
 Process control technology
Prozessleittechnik
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
 Filter for rolling oils and
emulsions
Filter für Walzöle und Emulsionen
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
Wagstaff, Inc.
see Casting machines 1.6
 Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
 Rolling oil rectification units
Hier könnte Ihr
BezugsquellenEintrag
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Walzölrektifikationsanlagen
ABB Automation Technologies AB
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
stehen.
Rufen Sie an:
Tel. 0511 / 73 04-148
Beate Schaefer
ALUMINIUM · 3/2010
75
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 Strip Annealing Lines
3.12 Air extraction systems
Bandglühlinien
Abluft-Systeme
 Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
3.17 Strip Processing Lines
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Bandprozesslinien
 Filtering plants and systems
Filteranlagen und Systeme
 Strip Processing Lines
Bandprozesslinien
 Colour Coating Lines
Bandlackierlinien
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
www.bwg-online.com
see Strip Processing Lines 3.17
 Lithographic Sheet Lines
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: bwg@bwg-online.de
Internet: www.bwg-online.com
Lithografielinien
www.bwg-online.com
see Strip Processing Lines 3.17
3.18 Production
Management systems
Produktions Management
Systeme
see Cold rolling units / complete plants 3.6
dantherm Filtration GmbH
Industriestr. 9, D-77948 Friesenheim
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245
E-Mail: info.de@danthermfiltration.com
Internet: www.danthermfiltration.com
 Stretch Levelling Lines
Streckrichtanlagen
www.bwg-online.com
see Strip Processing Lines 3.17
4production AG
Production Optimising Solutions
Carlo-Schmid-Str. 12, D-52146 Würselen
Tel.: +49 (0) 2405 4135-0
info@4production.de, www.4production.com
A PSI Group Company
3.14 Storage and dispatch
Lagerung und Versand
Could not find your „keywords“?
please ask for our complete
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
„Supply sources for the
aluminium industry“.
3.16 Coil storage systems
Bundlagersysteme
e-Mail:
anzeigen@giesel.de
SMS Siemag Aktiengesellschaft
see Rolling mill technology 3.0
76
ALUMINIUM · 3/2010
Lieferverzeichnis
4 Foundry
Gießerei
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
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
4.1
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
4.2 Heat-resistent technology
4.6 Foundry equipment
 Refractories
 Casting machines
Feuerfesttechnik
Feuerfeststoffe
promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
verkauf3@promat.de, www.promat.de
Gießereianlagen
Gießmaschinen
see Equipment and accessories 3.1
4.3 Conveyor and storage
technology
SeCO/WArWICk S.A.
see Heat treatment 2.4
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
www.mechatherm.com
see Smelting technology 1.5
Förder- und Lagertechnik
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
4.5 Mold accessories and
accessory materials
 Heat treatment furnaces
Wärmebehandlungsöfen
see Foundry equipment 4.6
Molten Metall Level Control
Ostra Hamnen 7
SE-430 91 Hono / Schweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
E-Mail: info@precimeter.com
Internet: www.precimeter.com
Sales contact: Jan Strömbeck
Formzubehör, Hilfmittel
 Fluxes
Wagstaff, Inc.
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
www.alu-web.de
ALUMINIUM · 3/2010
see Billet Heating Furnaces 2.1
 Solution annealing furnaces/plant
Lösungsglühöfen/anlagen
ernST reInHArdT GMBH
Postfach 1880, D-78008 VS-Villingen
Tel. 07721/8441-0, Fax 8441-44
E-Mail: info@ernstreinhardt.de
Internet: www.Ernst-Reinhardt.com
see Casting machines 1.6
 Mould parting agents
Kokillentrennmittel
Schröder kG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
www.schroeder-schmierstoffe.de
77
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4.8 Handling technology
Handhabungstechnik
Vollert Anlagenbau
GmbH + Co. kG
see Packaging equipment 2.3
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
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
 Manipulators
Manipulatoren
see Equipment and accessories 3.1
SerMAS InduSTrIe
E-Mail: sermas@sermas.com
See Casting Machines 1.6
4.9 Construction and
Design
Konstruktion und Design
THERMCON OVENS BV
see Extrusion 2
TrIMeT ALuMInIuM AG
niederlassung Harzgerode
Aluminiumallee 1
06493 Harzgerode
Tel.: 039484 / 50-0
Fax: 039484 / 50-100
Internet: www.trimet.de
4.13 Melt operations
Schmelzbetrieb
4.11 Metallic charge
materials
www.mechatherm.com
see Smelting technology 1.5
 Aluminium alloys
 Heat treatment furnaces
Metallische Einsatzstoffe
Aluminiumlegierungen
Wärmebehandlungsanlagen
see Billet Heating Furnaces 2.1
 Pre alloys / Vorlegierungen
 Recycling / Recycling
Chr. Otto Pape GmbH
Metalle
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
78
SeCO/WArWICk S.A.
see Heat treatment 2.4
 Holding furnaces
Warmhalteöfen
MeTALLHAndeLSGeSeLLSCHAFT
SCHOOF & HASLACHer MBH & CO. kG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
E-Mail: info@metallhandelsgesellschaft.de
Internet: www.metallhandelsgesellschaft.de
MeTALLHAndeLSGeSeLLSCHAFT
SCHOOF & HASLACHer MBH & CO. kG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
E-Mail: info@metallhandelsgesellschaft.de
Internet: www.metallhandelsgesellschaft.de
MArx GmbH & Co. kG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
E-Mail: info@marx-gmbh.de
Internet: www.marx-gmbh.de
 Melting furnaces
Schmelzöfen
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
E-Mail: info@bloomeng.de
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
engineering GmbH
see Casting equipment 3.1
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
E-Mail: info@bloomeng.de
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
SeCO/WArWICk S.A.
see Heat treatment 2.4
ALUMINIUM · 3/2010
Lieferverzeichnis
 Heat treatment furnaces
Wärmebehandlungsanlagen
Gautschi
engineering GmbH
see Casting equipment 3.1
4.15 Melt treatment devices
Schmelzbehandlungseinrichtungen
Metaullics Systems europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
E-Mail: info@metaullics.nl
Internet: www.metaullics.com
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
 Dust removal / Entstaubung
neOTeCHnIk GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
info@neotechnik.com, www.neotechnik.com
HerTWICH enGIneerInG GmbH
see Casthouse (foundry) 1.5
4.16 Control and
regulation technology
Steuerungs- und
Regelungstechnik
see Equipment and accessories 3.1
 Flue gas cleaning
Rauchgasreinigung
 HCL measurements
HCL Messungen
SeCO/WArWICk S.A.
see Heat treatment 2.4
4.14 Melt preparation
Schmelzvorbereitung
Ceraflux India pvt. Ltd.
F - 59 & 60, MIDC, Gokul Shirgaon,
Kolhapur - 416 234. Maharastra (India)
E-Mail: cerafluxindia@dataone.in
cerafluxindia@gmail.com
Web: www.ceraflux.com
OpSIS AB
Box 244, S-24402 Furulund, Schweden
Tel. +46 (0) 46-72 25 00, Fax -72 25 01
E-Mail: info@opsis.se
Internet: www.opsis.se
do you need
more
information?
E-Mail:
anzeigen@giesel.de
 Degassing, filtration
dantherm Filtration GmbH
Industriestr. 9, D-77948 Friesenheim
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245
E-Mail: info.de@danthermfiltration.com
Internet: www.danthermfiltration.com
4.19 Cast parts / Gussteile
TrIMeT ALuMInIuM AG
niederlassung Harzgerode
Aluminiumallee 1
06493 Harzgerode
Tel.: 039484 / 50-0
Fax: 039484 / 50-100
Internet: www.trimet.de
Entgasung, Filtration
drache umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
Gautschi
engineering GmbH
see Casting equipment 3.1
5
Materials and Recycling
Werkstoffe und Recycling
 Granulated aluminium
Aluminiumgranulate
Chr. Otto Pape GmbH
 Melt treatment agents
Schmelzebehandlungsmittel
Gautschi
engineering GmbH
see Casting equipment 3.1
ALUMINIUM · 3/2010
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
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: d.klein@ecka-granules.com
79
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6
Machining and Application
Bearbeitung und Anwendung
6.3 Equipment for forging
and impact extrusion
Ausrüstung für Schmiedeund Fließpresstechnik
 Hydraulic Presses
Hydraulische Pressen
6.1 Surface treatment
processes
Prozesse für die
Oberflächenbehandlung
 Cleaning / Reinigung
Henkel AG & Co. kGaA
siehe Prozesse für die Oberflächentechnik 6.1
LASCO umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
E-Mail: lasco@lasco.de
Internet: www.lasco.com
 Joining / Fügen
Henkel AG & Co. kGaA
siehe Prozesse für die Oberflächentechnik 6.1
Henkel AG & Co. kGaA
D-40191 Düsseldorf
Tel. +49 (0) 211 / 797-30 00
Fax +49 (0) 211 / 798-23 23
Internet: www.henkel-technologies.com
 Pretreatment before coating
Vorbehandlung vor der Beschichtung
Henkel AG & Co. kGaA
siehe Prozesse für die Oberflächentechnik 6.1
 Adhesive bonding / Verkleben
Henkel AG & Co. kGaA
siehe Prozesse für die Oberflächentechnik 6.1
6.2 Semi products
Halbzeuge
8
Literature
Literatur
 Technikcal literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of extrusion Technology
Giesel Verlag GmbH
Verlag für Fachmedien
Rehkamp 3 · 30916 Isernhagen
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157
Internet: www.alu-bookshop.de.
 Wires / Drähte
 Anodising / Anodisation
Henkel AG & Co. kGaA
siehe Prozesse für die Oberflächentechnik 6.1
drAHTWerk eLISenTAL
W. erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
E-Mail: info@elisental.de
Internet: www.elisental.de
Could not find your „keywords“?
please ask for our complete
„Supply sources for the
aluminium industry“.
Telefon:
0511/7304-148
Beate Schaefer
80
 Technical journals
Fachzeitschriften
Giesel Verlag GmbH
Verlag für Fachmedien
Rehkamp 3 · 30916 Isernhagen
Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157
ALUMINIUM · 3/2010
IMPRESSUM / IMPRINT
International
ALUMINIUM
Journal
86. Jahrgang 1.1.2010
Redaktion / Editorial office
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Fax: +41 274 555 926
Hüttenindustrie und Recycling
Dipl.-Ing. Bernhard Rieth
Walzwerkstechnik und
Bandverarbeitung
Verlag / Publishing house
Giesel Verlag GmbH, Verlag für Fachmedien, Postfach 120158, 30907 Isernhagen; Rehkamp 3, 30916 Isernhagen, Tel:
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ALUMINIUM · 3/2010
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81
VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special:
Die internationale Strangpressindustrie
Special: The international extrusion industry
Maschinen und Anlagen, Technologien, Projekte. Geplante Beiträge, unter anderem:
• Wettbewerb in der Strangpressindustrie – Analyse
unterschiedlicher Geschäftsmodelle
• Möglichkeiten zur Verbesserung der Energiekostenund CO2-Bilanz bei Bolzenerwärmungsanlagen
• Unternehmensporträt GIA Clecim Press
Wirtschaft
Machines and plants, technologies and projects.
Subjects, among others:
• Competing in aluminium extrusions – a normative
analysis exploring alternative business models
• Ways to improve energy costs and the CO2
balance of billet heaters
• GIA Clecim Press – a company portrait
• Composite extrusion and threading of
continuously reinforced aluminium profiles
Research
• Der deutsche und europäische Halbzeugmarkt
• Hot profile extrusion of different chip types of
aluminium alloy 6060
Sonstiges
• Kunst in Aluminium, Arbeiten des Künstlerehepaars Heike Rose und Bernd W. Schmidt-Pfeil
Erscheinungstermin:
Anzeigenschluss:
Redaktionsschluss:
Other topics
• Latest international news from the industry
Date of publication:
Advertisement deadline:
Editorial deadline:
02. April 2010
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82
ALUMINIUM · 3/2010
official
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Your advertising message reaches the fair’s visitors in several ways. The newspapers will be:
Sent in advance to all ALUMINIUM 2008 visitors
Laid out in the major hotels in and around Essen
Distributed at the entrances by special hostesses
Displayed at the trade press stand
If you want, displayed at your trade fair stand too
And to crown it all:
Both newspapers are being published with an increased
print run of
10,000 copies each – but with the same advertising rates!
More information and bookings:
Advertising Department:
Tel.: +49 (0)511 7304-0
Fax: +49 (0)511 7304-222
E-mail: anzeigen@giesel.de
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We are Official Media Partner for the event and the September issues of those
two titles are the only official fair newspapers authorised by the organisers!
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Giesel Verlag GmbH
Postfach 120158
D-30907 Isernhagen
Tel. +49 511 7304-0
Fax +49 511 7304-222
anzeigen@giesel.de
www.giesel.de
Committed
to the future.
Technology partner for the aluminum industry.
Whatever it is that you want to produce – as your
technology partner in plant construction, we strive
to make even the impossible possible. This reflects
our commitment to the markets of the future.
A constantly evolving spectrum of new product ideas
requires innovation and adaptation in plant design
and construction. Only a partner with expertise
covering the entire aluminum production process
can deliver real solutions here. Having recognized
the importance of mechatronic know-how early on,
we are always ready to implement the latest developments in aluminum production and processing.
As part of our X-Pact technology and automation
packages, all functional and operating simulations
are thoroughly tested. Especially in plant revamp and
conversion projects, this results in highly improved
ramp-up times.
The evolution of aluminum – SMS Siemag.
MEETING your EXPECTATIONS
SMS SIEMAG AG
Eduard-Schloemann-Strasse 4
40237 Düsseldorf, Germany
Phone: +49 (0) 211 881-0
Fax:
+49 (0) 211 881-4902
E-mail: communications@sms-siemag.com
Internet: www.sms-siemag.com