Ait may:june 2014

Volume 26 No 3May/June 2014

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

TODAY


TODAY


2Promoting the aluminium industry for 5

NEWS � CASTHOUSE � ENVIRONMENT

years

Solid competence for the aluminum industry

Being able to trust in the expertise and performance of every team member, is the foundation for success. To our customers around the world this means being able to count on a comprehensive offering in the area of aluminum produc-tion. From thermal pre-treatment to shaping and refi ning, we always meet the constantly rising challenges of the market.

Whether in new plant construction or revamp projects, our solid process know-how encompasses the complete produc-tion cycle, including the integration of the latest electrical engineering and automation solutions.

Confi dence through performance – SMS Siemag.

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SMS SIEMAG AG

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www.aluminiumtoday.com CONTENTS 1

Volume 26 No. 3 – May/June 2014

EditorialEditor: Nadine FirthTel: +44 (0) 1737 [email protected]

Consulting Editor: Tim Smith PhD, CEng, MIM

Production Editor: Annie Baker

SalesInternational Sales Manager: Paul [email protected]: +44 (0)1737 855116

Area Sales Manager: Anne [email protected]: +44 (0)1737 855139

Sales Director: Ken [email protected]: +44 (0)1737 855117

Advertisement ProductionProduction Executive: Martin Lawrence

Circulation/subscriptionsElizabeth BarfordTel +44 (0) 1737 855028Fax +44 (0) 1737 855034 email [email protected] subscription: UK £211, all other countries£230. For two year subscription: UK £380, allother countries £414. Airmail prices on request. Single copies £39

ALUMINIUM INTERNATIONAL TODAY ispublished six times a year by Quartz BusinessMedia Ltd, Quartz House, 20 Clarendon Road,Redhill, Surrey, RH1 1QX, UK.Tel: +44 (0) 1737 855000Fax: +44 (0) 1737 855034Email: [email protected]

Aluminium International Today (USO No; 022-344) is published bi-monthly byQuartz Business Ltd and distributed in the US by DSW,75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicalspostage paid at Emigsville, PA. POSTMASTER: send addresschanges to Aluminium International c/o PO Box 437,Emigsville, PA 17318-0437.Printed in the UK by: Pensord, Tram Road, Pontlanfraith,Blackwood, Gwent, NP12 2YA, UK

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ISSN 1475-455X

Cover picture courtesy of EGA

Aluminium International Today May/June 2014

2 LEADER & NEWS

UPDATES8 North America - Spring 2014:

Aluminum Association roundtable

9 Europe - New president for ALFED

10 India update - Moody’s downgrade threat:

A wake up call for Hindalco Industries

MINING15 Innovation in mining:

Rio Tinto’s Mine of the FutureTM programme

CASTHOUSE33 Aiming to change the casthouse game

40 EGA: Casthouse investments to support

regional downstream industry

42 MMM Ultrasonic Metallurgy

46 Dynamic Concept provides engineering

solutions

ENVIRONMENT48 LCA study bolsters aluminium’s sustainability

advantage

51 Keeping aluminium in the closed-loop

52 Fives Eco-Design programme

55 Sustainability in aluminium foundries

HEALTH & SAFETY57 Health and safety in the aluminium industry

EVENT59 11th Australasian Aluminium Smelting

Technology Conference

PERSPECTIVES60 Analysing the aluminium industry

FURNACES/HEAT TREATMENT25 Forced circulation can improve furnace

performance and efficiency

28 New burner technology: Turning low-grade

scrap metal into high-efficiency savings

COVER

51

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Volume 26 No 3May/June 2014


TODAY


TODAY



NEWS � CASTHOUSE � ENVIRONMENT

years

Mubadala Development Companyof Abu Dhabi and the InvestmentCorporation of Dubai hasannounced the officialincorporation of Emirates GlobalAluminium (EGA), formed byintegrating the two shareholders’respective aluminium interests.

The company will be managedby a board of directors that will bechaired by H.E. Khaldoon Khalifa AlMubarak, while H.E. SaeedMohammed Ahmed Al Tayer willbecome its vice chair. The boardwill also include H.E. Dr. Sultan AlJaber; Abdulla Kalban; Khaled AlQubaisi; Ahmed Yahia Al Idrissi;Abdul Wahed Mohammad AlFahim; and Khalid Al Bakhit.

EGA’s core operating entities are

Dubai Aluminium (Dubal) andEmirates Aluminium (Emal), whosecombined annual productioncurrently accounts for 50% of thetotal primary aluminium producedwithin the Gulf CooperationCouncil region. With EGA’s primaryaluminium production set to reach2.4 million tons per annum bymid-2014, the company will jointhe ranks of world’s top aluminiumproducers.

EGA also owns Guinea AluminaCorporation (GAC), a strategicbauxite mining and aluminarefining development project in theRepublic of Guinea. The companyplans to continue expanding alongthe aluminium value chain, fromsmelting to alumina refining and

bauxite mining; and will alsosupport the continued growth ofthe aluminium cluster in the UAE.

Abdulla Kalban, CEO andManaging Director of EGA said: “Iwould like to extend our gratitudeto the shareholders for theirsupport in establishing this globalbusiness.

“This is a proud day for EGA’shighly skilled employees, whorepresent a company led by UAENationals using technology that isunique to our company and theindustry. Combining the strengthsof Dubal and Emal creates anational champion fortechnological innovation andbusiness performance excellence.”

There is a definite themeacross the first couple of newspages.

It also seems to sum up myrecent flight path, as I waslucky enough to visit both theDubal and Emal smelters in theUAE, before paying a visit toAlba in Bahrain.

Both companies were busywith upcoming developments.Emal and Dubal were in thefinal stages of announcing theofficial incorporation ofEmirates Global Aluminium(EGA), while Alba wasbeginning preparation for thenext ARABAL conference inNovember 2014.

Despite tight schedules, Ienjoyed guided tours of eachof the smelters and readers willhopefully see the fruits of thislabour with a ‘Focus on theMiddle East’ feature in theJuly/August issue.

As always, this issue ofAluminium International Todayis full of interesting and topicalarticles, beginning with a lookat the challenges facing themining industry and Rio Tinto’sMine of the FutureTM

Programme (page 15). A dedicated ‘Furnaces/Heat

Treatment’ feature focuses onhow forced circulation canimprove furnace performanceand efficiency (page 25).

While a casthouse featureincludes an article from HycastAS about its game changingtechnologies (page 33) andEGA highlights how its recentcasthouse investments aredesigned to support theregional downstream industry(page 40).

Aluminium Bahrain B.S.C. (Alba)will host the 18th InternationalArab Aluminium (ARABAL)Conference in November 2014under the theme: “GCC: Analuminium power house”.

ARABAL is being hosted for thefourth time by the Kingdom ofBahrain, and this year, it is expectedto attract more than 700 delegates

including key decision makers andindustry leaders from all sectors ofthe aluminium industry in theregion and across the world.

Alba’s chief executive officer, TimMurray said: “As one of the majoraluminium smelters in the Gulfregion and the Middle East, Alba isproud to host ARABAL, an event ofinternational prominence for the

aluminium industry. The event isalso a testimony to the cooperationshared between the region’sprimary aluminium producers, thusemphasising our support for thesector.”

A Press Conference with moredetails will be held in due course toannounce further details of theevent.

Nadine FirthEditor

Game changing

EGA: Official incorporation

Alba to host ARABAL 2014

[email protected]

2 INDUSTRY NEWS www.aluminiumtoday.comCOMMENT

May/June 2014 Aluminium International Today

For up-to-date news & views www.aluminiumtoday.com

Qatalum stepped into 2013 withthe goal of becoming one of theworld’s top ten smelters, bysurpassing a number of targetsset out in the QatalumImprovement Programme (QIP).

The Programme aims toimprove the cash cost ofaluminium production over thenext five years. By the end of 2013the company surpassed itsimprovement target by 50%overall. The increase in efficiencywas done without compromisingsafety as part of its ongoingmission towards zero harm.

According to Deon Earle,Qatalum’s HSE Manager, a TotalRecordable Injury Rate (TRIR) of0.69 per million working hours,including directly supervisedcontractors, was achieved for theyear 2012 amounting to aconsiderably better performancethan the year’s target of 0.85.

“This indicates how seriousQatalum Management is aboutHSE and shows their continuedcommitment to safety,” he said.

Total recordable injuries atQatalum are at 12.5% of the totalrecordable injury rate published

by the International AluminiumInstitute (IAI) for 2012.

In regard to the QIP, Tom PetterJohansen, chief executive officerof Qatalum, urged employees tobuild upon the 2013 results andset new industry-leadingstandards in operationalexcellence, innovation andsustainability.

He stressed that the QatalumProduction System is instrumentalin reaching the objectives andvalues, which represent a solidplatform for leadership atQatalum.

Qatalum meets key targets

Sohar Aluminium (SA), hasapproved plans for theimplementation of a productivityoptimisation project that willboost output by 28,000 tonnes ofprimary aluminium annually.

The so-called ‘Amperage Creep’project is one of two initiativeslaunched by the company with theaim of optimising energy efficiencyand productivity at its smelter.

The other initiative concerns arevamp of the potline designed toachieve a reduction in energyconsumption.

“During the last two years, SAinitiated an upgrade of the potlining, thereby opening new

avenues in terms of currentefficiency and operatingamperage. The full deployment ofthese new state-of-the-art potswill be achieved by the end of theyear. This will lead to newproduction levels for SA,” saidSaid Mohammed al Masoudi,CEO.

“The SA team will also optimiseand improve the specific energyconsumption of the potline toreduce our aluminium cost pertonne. Meanwhile, we willcontinue to explore allopportunities for growth,including asset expansionscenarios,” he added.

Last December, shareholders ofSA approved an investment tosupport an amperage creepproject to reach an operating levelof 400kA in the coming years andboost production of primaryaluminium by an approximately28,000 tonnes planned to becompleted by 2019, Al Masoudistated. Both projects are in linewith SA’s efforts to maintain itsposition as a benchmark foraluminium smelting operationsaround the world. The Omanplant's Aluminium Pechineytechnology (AP3X) is globallyacclaimed as environmentallyfriendly and energy-efficient.

Abdulnoor Aluminium ExtrusionFactory (ALUNOOR), a newlyestablished company specialised infabricating aluminium profiles,announced the export of its firstshipment of 100% Qatari-madealuminium products to Oman and

the UAE.The shipment was inaugurated

by Jassim Abdul Noor, generalmanager of ALUNOOR, in less thantwo years from the establishmentof the factory located in MesaieedIndustrial City. Abdul Noor said:

“This shipment of aluminium pro-files to GCC countries is the start-ing point of more to world mar-kets, which will create added valueto aluminium export process, andwill reinforce the presence ofQatari products worldwide.”

Project to boost SoharAluminium output

ALUNOOR: First shipment

$32m coil coating project

www.aluminiumtoday.com INDUSTRY NEWS 3

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Alba awarded BritishSafety Council awardAluminium Bahrain B.S.C. (Alba)is the proud winner of theInternational Safety Award for2013 performance by the BritishSafety Council.

Competing with more than500 organisations spanning allsectors from the UnitedKingdom, Africa, Asia, theMiddle East and the West Indies,Alba won the much-covetedhonour for its commitment anddetermination to prevent work-place injuries and maintaininghealth and well being of itsworkforce during 2013.

The award was received byAlba’s chief operations officer,Isa Al Ansari on April 25, 2014at the Gala Dinner ceremonyheld in the UK (pictured below).

Bridgnorth to expandlithosheet capacityUK-based Bridgnorth Aluminiumplans to spend £41 million ($68million) expanding its lithosheetrolling and finishing capacityand enhancing its research anddevelopment facilities.

The new lithosheet capacityconsists of the installation ofan additional cold rolling milland a new litho finishing line.The capacity of the newproduction processes is around75,000 mt/year, more thandoubling the company'scurrent capacity, Bridgnorthsaid.

The scheduled start-up ofthe new processes is late2015.

The research and develop-ment laboratory, a newly con-structed unit which is in addi-tion to the company's currentdevelopment facilities, wasexpected to come into opera-tion in early May 2014.


HLG, operating as Leighton MiddleEast LLC in the Sultanate of Oman,has secured a contract with theOman Aluminium RollingCompany LLC (OARC) valued at$32 million for the Engineering,Procurement and Construction(EPC) of a Coil Coating Plant.

The Coil Coating Plant is part ofthe overall OARC’s new rollingfacilities that began commercialoperations in 2014, with the planthitting its full 160,000-tonproduction capacity by 2019.

HLG’s CEO and managingdirector, José Antonio López-Monís, said the plant project is animportant milestone for the Groupas it is the first EPC project thatHLG has been awarded in Sohar.

“Oman is an important marketfor HLG and we are grateful tohave been selected by OmanAluminium Rolling Company tobuild their plant facility. Thisproject award acknowledges thatwe have the local skills andexperience that our clients requiredelivering a best-in-class project,”he said.

The Coil Coating Plant facility isbeing developed as a downstreamunit to OARC’s rolling mill, with acapacity of 25,000 tonne perannum. The Coil Coating Plant willbe located directly across the roadfrom the existing Rolling Mill Plantin the Sohar Industrial Estate (SEI)on its own plot of approximately100,000 square metres.

Trucks from the existing Rolling

Mill Plant will deliver coils to thisplant for further processing. RonMarchbanks, OARC’s CEO, said:“HLG continues to develop astrong and credible reputation inOman and we are pleased topartner with them to deliver theCoil Coating Plant.” He added thatwith this project, OARC will expandits portfolio of added value ofproducts ranges.

Don Wrenn, OARC’s CoilCoating Plant Operations Director,added: “We are satisfied that thepartnership that we havedeveloped with HLG will helpassure the success of our project.”

In addition to the Coil CoatingProcess Building, the facility willencompass a Waste WaterTreatment Plant, Natural GasReducing Station, Scrap Yard, SolidWaste Yard, Hazardous WasteArea, Pond, Admin Building,Canteen, Change Room,Warehouse, Guard House andother site amenities.

4 INDUSTRY NEWS www.aluminiumtoday.com

UC Rusal: red mud products

Novelis marks evercan debut

Alcoa to curtail smeltingcapacity in Brazil

UC Rusal has announced the trialproduction of red mud-based fluxadditives at the Urals aluminiumsmelter (UAZ).

In 2014, the company plans toproduce its first scandiumconcentrate. Both new productswill be produced at a large outputrate.

In 2013 Rusal’s R&D proposed anew technology, and a pilotproduction area was launched totest the red mud recycling processat UAZ that later resulted in quite a

successful flux additives productioninitiative that supplied 1,000 mt offlux to MMK (Magnitogorsk),Tulachermet (Tula), Uralskaya Staland Severstal Scandiumconcentrate will be used inproduction of scandium andaliminium alloys.

In March 2014 UAZ startedbuilding its own scandiumconcentrate capacities (two tonnesa year) that are scheduled to becommissioned and also to be putinto operation immediately.

In 2014 the total investments onboth projects will be RUR 74 mln.

“At this moment the project is atits most challenging stage becausethe company has completed thelab tests and wants to start large-scale operations. And the trialproduction has shown brilliantresults, this is why we all believethat the project is reallypromising,” said Victor Mann,RUSAL’s Head of R&D andTechnology.

Novelis has announced that RedHare Brewing Company will launchthe world’s first commercial use ofevercan, the company'sindependently certified high-recycled content aluminium sheetfor beverage cans.

Red Hare craft beer packagedexclusively in cans made of Novelis'evercan aluminum sheet, which ismade of a guaranteed minimum90% recycled content, is expectedto be on store shelves beginning inMay 2014 in key markets through-out the south-eastern USA.

“This introduction marks thecommercial availability of theworld's first certified high-recycled

content aluminium beverage can,”said Phil Martens, president andchief executive officer for Novelis.“Working with Red Hare, we havedeveloped a proven supply chainto deliver this industry-first offer-ing to consumers, setting anexample that other beverage com-panies are sure to follow.”

“Novelis’ evercan is a perfect fitfor Red Hare,” noted Roger Davis,founder and CEO of Red HareBrewing Company. “The inde-pendent certification of theclosed-loop recycling processbehind evercan strengthens ourcommitment to employing thebest in sustainable business prac-

tices, making evercan a naturalextension of the Red Hare brand.”

Alcoa will curtail 147,000 metrictons of smelting capacity at its SãoLuís (Alumar) and Poços de Caldassmelters in Brazil.

The curtailments are expected tobe complete by the end of May2014.

In 2013, the company curtailed34,000 metric tons at Poços and97,000 metric tons at São Luís. Thenew curtailments will include theremaining 62,000 metric tons ofcapacity from the Poços smelter,resulting in a full curtailment of itsthree potlines. Another 85,000metric tons will be curtailed at SãoLuís.

“Across the globe, we are takingmeasures to curtail high-cost

smelting capacity that is notcompetitive and reshape our costprofile,” said Bob Wilt, President ofAlcoa Global Primary Products.“These are difficult but necessaryactions in support of Alcoa’sstrategy to lower the cost base ofour upstream businesses.”

As a result of the smeltercurtailment, the Poços refinery willalso reduce production accordingly.The mine, aluminium powder plantand casthouse at Poços willcontinue normal operations, as willthe refinery at São Luís. Other Alcoaoperations in Brazil are not affected.

“We know how deeply thisdecision affects our employees, ourcontractors and our communities,”

said Aquilino Paolucci, President ofAlcoa Latin America and theCaribbean.

In May 2013, Alcoa placed460,000 metric tons of smeltingcapacity under review. Once allannounced curtailments andclosures are complete, Alcoa willhave approximately 800,000 metrictons, or 21%, of smelting capacityoffline.

Total restructuring-relatedcharges associated with the Brazilcurtailments in the first quarter areexpected to be between $40 millionand $50 million after-tax, or $0.04to $0.05 per share, of whichapproximately 30% would be non-cash.

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House built entirely ofaluminiumJapanese architect TerunobuFujimori has crafted a privatehome clad entirely with a softmetallic coat.

Situated in a small provincialtown near tokyo, the property,entitled ‘soft-hard aluminiumhouse’, is flanked by two typicalresidential structures, allowing itto catch the eye.

The gabled end of thedwelling is cantilevered, provid-ing space for parking at groundlevel, while a small garden isfound at the rear of the design.

Hydro agrees to sellaluminium casthouse Hydro has entered into a bind-ing agreement to sell its specialalloy aluminium casthouse inHannover to IQ IndustrialHolding S.à r.l. (Luxembourg), aprivate industrial holding groupwith operations across Europe.

The Hannover casthouse isfocused on special aluminiumalloys, mainly hard alloys for theaerospace industry.

Through the agreement, IQIndustrial Holding will acquire100% of the shares in HydroGiesserei Hannover GmbH.

The Hannover casthouse wastaken over by Hydro through theacquisition of VAW aluminiumAG in 2002 and is considerednon-core business. The cast-house supplies its hard alloyproducts mainly to a customerlocated wall-to-wall.

The Hannover casthouse hasaround 30 employees and pro-duced approximately 12,000tonnes of aluminium products in2013.

The transaction is expected toclose during the second quarterof 2014.


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Constellium to buildtwo casthouses

In light of the upcoming review ofEU waste legislation, the EuropeanAluminium Association (EAA) callsfor higher recycling targets and aphase out of landfilling of end-userecyclable goods.

The European aluminiumindustry strongly supports moreambitious recycling targets and agradual phasing out of landfilling.Together with better collectionschemes and innovative sortingtechnologies, these are the

preconditions for an effective andsuccessful circular economy.

EAA director general Gerd Götzstates: “Bold policy measures areneeded to secure the availability ofaluminium scrap in Europe, a keyresource for increasing recyclingrates and one of Europe’s energysecurity components. We arecalling for investment andinnovation in the fields ofcollection and sorting, as well asgreater consistency in reporting

procedures, clearer definitions ofrecycling and the recognition ofaluminium as a ‘permanentmaterial’.

“Stopping illegal scrap exportsand reducing scrap leakage is alsoessential to reduce Europe’sdependency to resource andenergy imports. The first andminimum step would be to set upcredible metal scrap exportmonitoring systems.”

6 INDUSTRY NEWS

Constellium has announced that itwill increase the industrial capacityof its Issoire (France) plant to meetaccelerating demand for itsAIRWARE technology.

Building on the experience ofConstellium’s first casthouseinaugurated in March 2013, whichis already producing AIRWARE atindustrial scale, the two newcasthouses are expected to startand ramp-up production in 2015and 2016 respectively.

These two additional casthouseswill allow Constellium to nearlytriple its production of advancedsolutions based on its AIRWAREtechnology, which was selected to

be part of major new aerospaceprogrammes including Airbus’A350 XWB, Bombardier’s CSeriesand SpaceX’s Falcon 9 Launcher.

“This strategic movedemonstrates our ability to notonly be the leading innovator inour field but also scale up theproduction of AIRWARE, ourpatented range of aluminium-lithium alloys,” stated Jean-Christophe Figueroa, President ofConstellium’s Aerospace andTransportation Business Unit. “Ourinvestment, which will allow us tomeet greater demand thananticipated under contract, clearlyillustrates our long-term

commitment to strengthen ourleading position in the aerospacemarket. And we intend to continueto expand our industrial platformin the future to accompanycustomer’s needs,” Figueroaadded.

EU Waste policy reviewIN BRIEF

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Sapa: Educational seminarsThe Sapa Profile Academyprovides an overview of variousopportunities with aluminium,from inception to production.

These training sessions aregeared toward designers andengineers, as well as plant,project, production andpurchasing managers.

Conducted over two days bySapa experts, specific topicsinclude:Metallurgy and AlloysDesign and ProductionSurface Treatment andCorrosionBending and HydroformingJoining and WeldingTolerances

The dates and locations forthe 2014 Profile Academysessions are:May 14-15 Toronto, OntarioAugust 6-7 Portland, Oregon(Building & Constructionfocus)September 10-11 South Bend,IndianaNovember 12-13 City ofIndustry, California

For more information,contact: Jessica Emery,Buchanan Public Relations forSapa Extrusions North AmericaT: (610) 649-9292E: [email protected]

Alcoa signs agreement withSpirit AeroSystemsAlcoa has signed a long-termagreement to supplyaluminium sheet to SpiritAeroSystems, Inc. in a contractvalued at approximately $290million over five years.

On April 8, Alcoa increasedits 2014 global aerospacegrowth expectation by onepercentage point from 8% to9%, on strong demand forboth large commercial aircraftand regional jets andcontinued growth in thebusiness jet market.

Alcoa will provide Spirit withaluminium sheet products forfuselage skins from itsDavenport (Iowa) facility,which houses the world’slargest and most advancedaluminium rolling mill.

Alumina Rondon developmentThe State Environmental Council(COEMA), an agency linked to theState of Pará Department of theEnvironment (SEMA), northernBrazil, approved the granting ofthe Preliminary License (PL) to theAlumina Rondon project, aVotorantim Metais development tobe built in the city of Rondon doPará, southeastern Pará.

The project comprises theconstruction of an alumina refineryintegrated to the bauxite mine,and will require investments in theorder of R$6.6 billion. WithCOEMA'S approval, VotorantimMetais completes the first stage ofthe environmental licensingprocess, as required to kick offproject operations.

“The approval of the Preliminary

License represents the society’strust in Votorantim Metais andAlumina Rondon, especially withregard to the company'senvironmental responsibility andthe world class standard of theenterprise,” said Sergio Carvalho,the coordinator for Sustainabilityfor Alumina Rondon.

COEMA ratified the TechnicalReport issued by SEMA, whichassessed the project positively,considering its environmentalfeasibility and relevance to thedevelopment of the State of Pará.The completion of the first stagefrees Votorantim Metais to securethe Installation License (IL), thenext-to-last stage of the licensingprocess, which will be completedwhen the Operating License (OL) is

secured.Alumina Rondon is the

company’s largest project in themining area, and is expected tostart operating by 2017. In theinitial phase, Alumina Rondon willproduce 7.7 million tonnes ofwashed bauxite and three milliontons of alumina, which will rankthe refinery as the second largest inthe world.

Constellium 34 metre wing panels

Aluminium International Today

Novelis has announced thecommissioning of a newaluminium slitting and packing lineat Aluminium Norf GmbH(Alunorf), its joint-venture facility inNeuss, Germany.

With an investment ofapproximately €15 million, it will

increase the plant’s finishingcapacity for beverage can sheet.

“This investment reflects thesolid growth of the aluminiumbeverage can market in Europe,which has resulted in significantlyincreased can sheet sales,” saidPierre Labat, vice president and

general manager, Can for NovelisEurope. “Novelis Europe iscontinuously investing tostrengthen its market leadership byincreasing can sheet productionand used beverage can recyclingcapacity to meet customers’requirements.”

Novelis: Can sheet capacityJune11-13 METEFAn international metalsexhibition covering extrusions,diecasting, foundry, rolling,finishing, machining,fabricating and recycling.www.metef.com/ENG/home.asp

23-28 “Aluminium-21/Extrusion”Conference programme willcover status and main trendsof the extrusion market.www.eng.alusil.ru

July9-11 Aluminium ChinaExhibition and conferencecovering all aspects of theglobal industry.www.aluminiumchina.com/en/

October7-9 Aluminium 2014Exhibition and conferencecovering all aspects of theglobal industry.www.aluminium-messe.com

November11-14 Metal Expo 2014Exhibition showcasing wholerange of ferrous and non-ferrous productswww.metal-expo.ru/en/

17-21 Aluminium RollingTechnology CourseFrom Innoval Technology, thecourse covers all the keyaspects of hot and cold rollingof aluminium flat products,and is aimed at engineers andmanagers in the aluminiumproduction and processingindustry.www.innovaltec.com/rolling_tech.htm

December6-11 11th AustralasianAluminium SmeltingTechnology ConferenceA week filled with up-to-datetechnical information, researchfindings and panel discussionson technical issues of concernto the industry.www.11aastc.com

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8

Spring 2014: Aluminum Association roundtableMyra Pinkham* provides an overview of the current state of the US aluminium industry.

NORTH AMERICA UPDATE


“It has been an exciting few months forthe aluminium industry; from theannouncement of the aluminium-intensiveFord F-150 to the establishment of the U.S.Department of Defence-led AmericanLightweight Materials ManufacturingInnovation Institute (ALMMII) – a public-private partnership based in Detroit whosemission is the development of lightweightmaterials for use in everything from newhulls in Navy ships to lighter and saferautomobiles,” Layle “Kip” Smith, presidentof Noranda Aluminum, said during a pressbriefing at the Aluminum Association’sspring meeting in San Antonio, Texas.

“In both cases this news underscoreshow aluminium is well positioned toprovide solutions to modernmanufacturing challenges as the USA andthe rest of the world strive for a more fueland energy efficient future,” he continues.

While there is no question that themarketplace in general has been andcontinues to be very volatile, Heidi Brock,president and chief executive officer of theAluminum Association, states that theindustry has demonstrated that it islooking toward the long-term in finding aplace for its metal on the demand side.

“We are really encouraged by theindustry’s position in North America,” shesays, noting that the industry shippedmore than 24 billion pounds of aluminiumlast year, which was its highest volumesince 2007, with demand increasing byabout 30% in the past four years. This, shesays, includes 14% year-over-year growthin the transportation sector, eight percentgrowth in the electric wire and cablingmarket and six percent growth in bothbuilding and construction and consumerdurable goods.

The Aluminum Association officersvoiced optimism that the Ford F-150 willbe one in a long line of high volume lightvehicles that will see significant increases inaluminium content.

Marco Palmieri, president, NorthAmerica for Atlanta-based Novelis Inc.,observes that while the average gasolinemileage for North American cars and lighttrucks is now about 29 miles per gallon(mpg), by 2025 that number will have togo up to 54.5 mpg. “That is a big increaseand aluminium is a great material to help

the automotive industry achieve that,” hesays. “All the automotive OEMs haveexpressed interest in aluminium and we areworking with them to develop ways to useit in next generation cars and light trucks.”

It is in recognition of the importance ofdeveloping and commercialising advancedlightweight materials and manufacturingtechnologies and of educating and trainingthe manufacturing supply chain on how towork with this material, that late inFebruary the Obama administrationannounced the formation of ALMMII,which is one of the 45 or so plannedpublic-private manufacturing innovationhubs that the U.S. government intends toset up as part of its National Network forManufacturing Initiative.

According to Alan Taub, who, inaddition to being a professor of materialsscience and engineering at the Universityof Michigan, is the ALMMII’s chieftechnology officer, the mission of theinstitute is to ensure that the USA is aleader in the application of innovativelightweight metal production andcomponent/subsystem manufacturingtechnologies.

He says ALMMII is to serve as anessential bridge between basic researchand final product commercialisation forvarious lightweight metals, includingaluminium, advanced high strength steels,titanium and magnesium, for not only avariety of transportation applications –everything from new hulls in Navy ships toairplanes, heavy duty trucks, rail and lighterand safer automobiles – but for energy,medical and consumer applications as well.

“ALMMII’s facilities and technologydevelopment capabilities provide the rightsolutions to promote Americancompetitiveness, energy-efficiency, defencereadiness and economic growth,” he says.

The ALMMII founding members include34 manufacturing companies, includingAlcoa Inc., NanoSteel Co., Luvata,Materion Corp., RTI International Metals,TIMET, Steel Warehouse Co., Boeing Inc.,General Electric, and Lockheed Martin.

Brock could not say what impact theinstitute is likely to have upon thealuminium industry. “There are a lot ofcompanies and associations that are nowjust coming to the table and looking at the

research agenda they have put together,”she explains. “But aluminium is definitelyone of that materials that is representedand we are interested in growing thatpresence.”

Smith says the aluminium industry hasalso taken moves to become more energy-efficient, as is evidenced by a new lifecycleassessment report released by theassociation in January, which showed anearly 40% drop in the carbon footprint toproduce each tonne of primary aluminium.

One way that it has done this is byincreasing recycled content, which Palmierisays has been a big focus for Novelis. Thecompany is looking to raise the recycledcontent in its products to 80% by 2020,partly through increased closed loopmanufacturing. He says that the companyhas already increased its recycled contentto 43% from 35% and is now on its way tomeet its intermediate target of 50%recycled content by 2015.

This begs the question whether therewill be enough aluminium scrap availableas aluminium demand grows and therecycled content of that aluminiumincreases.

“There is never enough aluminium scrap.It is a highly sought after item. It is asource material for all of the secondaries,”Garney B. Scott, president of Scepter Inc.,admits. However, on the up side, heobserves that the recycling rate for usedbeverage cans has increased to 67% in2012 (the latest year that such statistics areavailable) and, according to the latestAluminum Association statistics,aluminium scrap exports are down 350million lbs year-on-year.

As a result there hasn’t been a drasticdecrease in supply – at least not yet, hesays. “But many companies are seeking outthis scrap and more and more companiesare looking to consume scrap as an input.”

“We are very excited about the modernmetal image of aluminium and to be partof the U.S. manufacturing renaissance,”Brock says. “We believe the demandfundamentals are very positive for ourindustry.”

Palmieri agrees. “What we are seeingnow is the kind of growth rates we haven’tseen in about 30 years, when aluminiumreplaced steel in beverage cans.” �

*North American correspondent

The Ford F-150

Standing at the helm of one ofShropshire’s leading manufacturingbusinesses, Simon MacVicker is a manundaunted by big challenges.

But attributing to Simon a “steely resolve”would perhaps be inappropriate, given thathe’s the managing director of BridgnorthAluminium. Over the next two years he willbe helping to further the interests of thealuminium sector as president of theAluminium Federation (ALFED).

“It’s a real privilege to represent theindustry in this way and I’m very excitedabout tackling some of the challenges ourmembers face,” Simon said.

“One of the biggest issues we need totake on is the significant tax andregulatory burden holding the sector back.I met with Business Minister MichaelFallon in mid-January and he was verysupportive of our messages about theneed to cut energy taxation and red tape.But we need to keep delivering thatmessage to Government to help ensure


New president for ALFEDMark Binnersley* introduces Simon MacVicker, managing directorof Bridgnorth Aluminium, and his work in the UK industry.

*Account manager, Clark Associates

action is taken.”Simon added: “We’ve all heard over the

past year how the automotive industry isembracing aluminium to make cars morefuel efficient and cut carbon emissions;that’s just one way the metal is providinga solution. But it’s also used in most solarpanels, so is vital to the generation ofclean energy.

“As an industry we really need tocommunicate these environmentalbenefits to our policymakers who, whilsthaving the best intentions, have createdlegislation that has stood in the way ofaluminium providing technologicalsolutions to reduce mankind’s impact onthe planet.”

Driven largely by environmental taxes,spiralling energy costs have contributed tothe closure of two of Britain’s threeprimary aluminium smelter productionplants. Since 2010, Britain’s primary

aluminium output has dropped by 87%from 361,000 tonnes per year to just47,000 tonnes. That said, 20,000 peopleremain employed in aluminiummanufacturing and supply in the UK,generating an annual turnover of £3.2billion.

“Frankly, I can’t envisage a time whenlost primary aluminium production“reshores” to the UK, but what we can dois protect and grow the manufacturingand supply industry that remains here.

“From a global perspective, the UK is anincredibly attractive proposition because itcomprises a close-knit cluster ofaluminium businesses providingmanufacturing supply chain solutionsincluding primary and secondaryproduction, rolling and extrusions,finishing, shaping and forming, and ofcourse the whole recycling loop. We needall these elements to be strong, because ifone weakens that could affect the entiresector.” �

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While the Aditya Birla Group behemothhas taken all possible steps to addressproblematic issues, external and internalfactors beyond its control have hit thecompany’s operating margins severely,resulting into lower income estimates thisfinancial year. Analysts, however, forecasta turnaround in Hindalco’s net profit in thefinancial year 2014-15 with an estimatedjump in the company’s consolidatedannual revenue. Squeezed between highercost of production and lower realisationdue to global oversupply, Hindalco’sprofitability will improve with the recoveryin aluminium prices at least to the level ofthe cost of production. Also, Hindalco’soverseas subsidiary Novelis has been acause of worry due to its extremely overleveraged debt.

Moody’s downgrade threatNovelis’ business model is unique in itself.The company exports most of its productsto the electronics and high-end specialityand automotive makers. Novelis, whichwas taken over by Hindalco in 2007 for $6billion, is the world’s largest producer ofrolled aluminium products. But, asubstantial loan on its books hasthreatened investors of Hindalco Industriesfor future recovery. In March 2013, Novelisreported total debt at $5.4 billion, which islikely to moderate marginally to $5.23billion by March 2016.

Global rating agency Moody’s hasplaced the debt of Novelis under review fora possible downgrade on concerns ofdebt. Moody's has placed the debt ofNovelis, the Aditya Birla group’s aluminiumcan maker arm, under review for

downgrade to a probable default rating.This was because of the company’ssubdued operational performance in therecent past. Moody’s said many challengeswere facing the aluminium industry,despite an improving shipment profile.These include weakness in the NorthAmerican beverage can market and anincreased competitiveness in the Asianmarkets, which continue to exert pressureon earnings and margins of the company.Novelis is facing a relatively high capitalexpenditure, as it continues its strategicinvestments in automotive sheet finishingcapacity to meet increasing demand foraluminium from the automotive industry.

The review of downgrade was due tocontraction in the earnings before interestand tax (EBIT)/interest ratio to 1.7 for theyear ended December 2013, and an

increasing leveraged position, as seen bythe debt/EBIDTA (earnings before interest,tax, depreciation and amortisation) ratiofalling to 6.9 from 5.6 for the financial yearended March 31, 2013. This reflects alower EBIDTA level and increased debt due.The concerns raised by Moody’s can beaddressed if aluminium prices and premiaimprove.

Goutam Chakraborty at the brokerageEmkay Global, therefore, is concernedabout the sustainability of a burgeoningaluminium premia (the excess over themetal’s LME price). The Aditya Birla Grouphas, however, said both Novelis andHindalco are “rock solid companies”,adding there is no question of a default byNovelis.

The impact of a possible downgrade ofNovelis, however, would be insignificant

10 INDIA UPDATE www.aluminiumtoday.com


Moody’s downgrade threat: A wake up call for Hindalco Industries

One of India’s largest private sector aluminium producers, Hindalco Industries Ltd, iscurrently under pressure to protect its operating margins due to lower realisation than thecost of production, following a sustained fall in global prices of aluminium and its key rawmaterials. By Dilip Kumar Jha*

*Correspondent

Particulars FY13 FY14 FY15 FY16

Hindalco Industries’ business guidance (INR bn)

Revenue 801.93 871.55 985.68 1046.59

Net income 29.39 21.86 22.00 24.90

Earning per share (INR) 15.4 11.4 11.5 13.0

Disclosure : FY = Financial Year ending with March 31

Particulars FY13 FY14 FY15 FY16

Novelis’ business guidance ($ mn)

Net sales 9739 9821 10821 11069

Total shipment (‘000 MT) 2964 3151 3451 3511

EBITDA 937 842 987 1042

Total debt 5427 5527 5327 5227

Interest expenses 298 305 325 285

Disclosure: FY = Financial Year ending with March 31

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on Hindalco, as analysts believe. “Novelishas an EBIDTA generation of $1 billion ayear and accounts for 60% of Hindalco'sconsolidated EBIDTA. Financially, Novelis isin a comfortable position,” said CentrumBroking’s Abhisar Jain.

Moody's feared that the future ofNovelis' debt would be based on theoutlook for shipments and conversionpremiums within the company'sgeographic operating regions and itsability to reduce costs and planned capitalexpenditure levels. “In case, the currentdebt level continues, a downgrade wouldfollow,” Moody said and added that itwould review with focus on the timehorizon over improved performance interms of high realisation (due to thebenefit of higher value-added automotivebusiness). During the 12 months toDecember 31, 2013, Novelis generated$9.8 billion in revenues and shipped 2.8million MT of rolled aluminium.

In fact, the net profit of Hindalcocontinuously declined over the last threeyears and analysts forecast it to marginallyrecover in the FY 2014 - 15 after fallingaround 20% in the previous FY 2013 - 14.After stagnation in FY 2013 - 14, thecompany’s revenue is set to decline byaround six percent in FY 2014 - 15.

Fear intensifiesICICI Securities in its latest report said thatas dust over domestic earnings settles andsignificant flak in consensus estimatesbecomes apparent, mainly driven by arecovery in aluminium price and low costassumptions in the stand-alone business,one wonders what can help save earningsdowngrade cycle for Hindalco Industriesand limit underperformance of the stock.One such theme is the increasing shipmentof automotive body sheets from Novelis,which is expected as the next volume andmargin trigger for Hindalco. “Our analysisof automotive aluminium penetration inthe US market makes us cautious/skepticalon volumes. Given the spate of capacitiesthat have been announced in the US(above 1 million MT) by suppliers includingAlcoa/Novelis/Constellium, we feel demandwill under perform, making the absoluteEBITDA increase coming out of thesegment a very slow process,” the reportsaid.

Muted demand visibility also implieslimited investments will go into USautomotive hot rolling lines, taking out amajor capex risk and perhaps openingroom for dividends. Following Ford’s F-150launch, demand/supply for automotivealuminium in the US looks unfavourableconsidering the requirement on trucks todrive aluminium demand till 2020. Giventhe capacities that have been announcedin the US (over 1 million MT) byAlcoa/Novelis/Constellium, demand is likely

to remain subdued. Also, looking at the USautomotive aluminium demand scenario,incremental investments into the upstreamwill be hard to come by. The demandscenario in Europe looks much betterplaced. This shows that Novelis’ capex candelay dividend repatriation to the parent.

The decline in consolidated net profit islikely to get partly offset through increasesales from two of Hindalco’s domesticprojects – Mahan and Aditya Smelter – thetwo ambitious projects of the companyscheduled to commence commercialproduction in 2014. Hindalco’s domesticearnings may rise a bit, increase utilisationfor Utkal Alumina and Mahan and Adityasmelters for FY15 and FY16, which willhelp increase EBITDA.

“We are extremely disinclined to increasethe earnings of Novelis on the back of theauto theme, which takes out the last ray ofhope for earnings bottoming out or givingany impetus to us to take a favourableview on the company’s profit. Theestimated decline in consolidated profitwill take into consideration higherdepreciation and interest. The standaloneprofit, however, is going to witness slightlyup, as the company incrementallycommissions Mahan and Aditya smelterprojects in FY15,” the report said.

Capacity expansion: Coal concernsAlumina and aluminium capacity additionsbeing carried out by Hindalco, especially atUtkal Alumina, are steps in the rightdirection. Hindalco’s domestic aluminiumannual capacity is being expanded fromthe current 560,000 MT to 1.28 millionMT by FY16 (through the Mahan andAditya projects). The company’s aluminaproject is among production units thathave the lowest costs globally. Thecompany started alumina production inDecember 2013. Considering thatEdelweiss has increased their sales volumeassumptions to 0.85 million MT and 1.3million MT from 0.75 million MT and 1.1million MT earlier for FY 2015 and FY 2016respectively. They have also raised theirFY16 consolidated EBIDTA by two percent.

However, the company’s medium-termprofitability depends on coal. In a recentreport, Antique Stock Broking said: “Theplanned capacity expansion is integratedwith respect to alumina by the Utkalrefinery (1.5 million MT/year) and captivebauxite linkage. However, captive coalavailability for the Mahan project is stillabout 18-24 months away (post the stage-II forest clearance) and uncertainty over theTalabira coal block for the Aditya smelterraises concern on the profitability of theseprojects.”

Power is an important cost element inthe production of aluminium. The returnratios for the Mahan and Aditya smelterswould be suppressed and the projects

would lose value until there was animprovement in aluminium prices andcaptive coal was available for the projects.

Sustained lower aluminium price:A worryDebu Bhattacharya, managing director ofHindalco Industries recently said that thecost of aluminium production works out to$1900/MT. Realisation below this level isloss-making for aluminium producers,resulting in pressure on margins and costand production cuts. By contrast, thealuminium price fell to $1680/MT, morethan a month ago. This means, aluminiumproducers incurred a loss of $220/MT atthis price level.

While the aluminium price has recovereda bit to trade currently at $1815 on theLondon Metal Exchange (LME), the metalis still traded below the level of cost ofproduction. Global majors have alreadyinitiated production cuts to protect theirlong term business interests. Indianproducers are awaiting a revival in globalprices and are meanwhile, adoptingstrategies to reduce manpower and energyto cut overall cost of aluminiumproduction. Girirraj Daga at Nirmal BangInstitutional Equities feels considering theslowdown in China, the upside toaluminium prices remains limited onsupplies still exceeding demand.

JM Financial says global aluminiummarkets were oversupplied by 1.57 millionMT in 2013. Another two million MT ofadditional capacity is being ramped up, ofwhich 1.2 million MT is scheduled for2014. This will offset any production cut(by other players). Despite the recent run-up in aluminium premia to $450/MT, anycut in waiting time for physical deliveries,with the implementation of new LMEnorms across warehouses, could lead tocorrection in premia from the currentrecord levels. Aluminium inventories on theLME currently stands at 5.4 million MT,remaining near record highs, which wouldrestrict the possibility of an upsurge inaluminium prices. Total global inventoriesare estimated at about 12 million MT.Chakraborty at Emkay Global, too, isconcerned about the sustainability ofpremia at these levels. Further, increase ininterest rates, as the US Fed continues itstapering programme could make financingdeals infeasible. JM continues to remainunderweight on aluminium majors such asHindalco.

Rising hopesFollowing some key capacity closures(globally) and curtailments, rally inaluminium prices since mid-February led toa smart 25% rise in the Hindalco stock.Analysts expect good growth in volumes,driven by satisfactory progress atHindalco’s Utkal project. �

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15www.aluminiumtoday.com MINING


Rio Tinto is a major mining company and aworld leader in the supply of metals andminerals. Its key products are aluminium,copper, diamonds, industrial minerals (i.e.borax, titanium dioxide and salt), energyproducts (which are coal and uranium),gold, and iron ore. Exploration andTechnology & Innovation (T&I) groupssupport its operations.

The company is strongly represented inAustralia and North America, and also hassignificant businesses in Asia, Europe,Africa and South America, employingaround 66,000 people in more than 40countries. Rio Tinto has a clear andconsistent strategy, which is the pursuit ofgreater value for its shareholders. Althoughmining is not known as a technologyfocussed business, the company believesthat there is good commercial reason toinvest in emerging technologies. Researchand development is playing a key role inensuring it remains a global leader in theresources sector.

The research and development groupwithin T&I is called Rio Tinto Innovation.This group was formed in 2007 andfocuses primarily on the development anddeployment of step-change technologiesto address the challenges of the miningbusiness. As you will probably know, RioTinto Alcan has a technology group thatsupports the aluminium business and theyare well qualified in this respect. Rio TintoInnovation is the custodian of the Mine ofthe FutureTM programme and uses anetworked technology developmentmodel, allowing them to leverage a largeresource of world-class experts.

Innovation hubsThere has been much discussion on how tomaintain a long-term R&D focus in avolatile global economic environment andan industry that is consolidating. Rio Tinto

Innovation believes that the solution is tobuild partnerships and networks. There aresmall Innovation teams close to Rio Tintooperations in Brisbane, Perth, Salt Lake Cityand Montreal. These teams of specialistsmanage and support step changeimprovement projects but have nolaboratories, as such. A strong IntellectualProperty management team, absolutelyessential to the network model, is based inMontreal.

Network modelRio Tinto Innovation has created a widenetwork of both formal long-term R&Dalliances with world-class institutions andstrategic technology partnerships withleading companies, to develop andultimately commercialise its Mine of theFuture™ technologies. This approachrecognises that many of the new tools,techniques and technologies required tocapture fundamental shifts in performancewill come from outside the business. Our

partnerships are shown in Fig 1. There arefive global Centres of Excellence based atleading universities and colleges inAustralia, Canada and the UnitedKingdom.

Along with these alliances, there is alsothe Rio Tinto Innovation Centre, apartnership in India, which will build onthe work of the Centres of Excellence todeliver the technologies to Rio Tintooperations across the globe. The Centreprovides industrial automation andcontrol, design, software and generalengineering services.

The technology partnerships link RioTinto with key Original EquipmentManufacturers (OEMs) to deliver newtechnologies. You may also have seen inthe media announcement of the recentMemorandum of Understanding withChinalco. This will see the companiesinvestigating the possibility of jointlydeveloping next-generation miningtechnologies.

Innovation in mining: Rio Tinto’sMine of the Future programme

At the recent TMS 2014 conference, Geoff Bearne* discussed the challenges facing the miningindustry and the emerging technologies designed to tackle them. He presents his ideas here, exclusivelyfor Aluminium International Today.

*General Manager, Technology Delivery Systems, Rio Tinto Technology & Innovation

Formal long term alliances with world class institutionsprovide access to stable research resources to pursuetargeted Rio Tinto programmes.

Strategic partnerships and MoUs with leading globalorganisations to help develop technology to commercialoutcomes

1 Centre for Mine Automation2 Centre for Advanced Mineral Sorting3 Centre for Underground Mine Construction4 Centre for Advanced Mineral Recovery5 Centre for Emergent Technologies6 Rio Tinto Innovation Centre

7 University of Western Australia8 Komatsu9 e2v

10 Tomra11 Herrenknecht

Rio Tinto centres

Technology parterships

Rio Tinto innovation hubs

Fig 1. Rio Tinto innovation network

TM

16 MINING www.aluminiumtoday.com


ChallengesThe mining industry faces many challengesand opportunities. I have chosen tocategorise these as either societal orgeological. From a societal perspective, onthe one hand there is the extraordinarydemand for minerals and metals drivenlargely by urbanisation and lifestyleimprovement in the developing world. Forus, this is a good thing. But we mine andexploit from the earth, which is owned bycommunities and has many stakeholders.Their expectations are increasing. Clearlywe must be good neighbours, meet ourcorporate social responsibilities and ensurethe health and wellbeing of ouremployees.

At the same time, from a geologicalperspective, much of the low hanging fruithas been picked and ore grades havefallen. The search for high quality mineraldeposits is driving miners to more remoteareas and deeper into the ground. Both ofthese directions increase risks and costsand force the need for larger scaleoperations with their associatedinvestments. You will be aware that thesituation is similar in the aluminiumindustry, except that it is low emissionselectrical energy that is the scare resource.

In summary, miners have to continue tomeet the demand, mitigate the cost andproductivity challenges, and survive thevolatility of the commodities business. Webelieve that innovation will be the key torising to these challenges.

Mineral supplyTo illustrate the minerals demand story, Fig 2shows expenditure on copper, aluminium,iron ore and coal as a function of GrossDomestic Product per capita, as well at thepopulation distribution associated withdifferent levels of GDP per capita. As onemight expect, the expenditure on theseproducts increases (at different rates) asthe standard of living increases and thepopulation is shifting to the right,dominated by changes in China and India.The increased demand associated withurbanisation is putting pressure on the

supply of minerals. Figure 3, which showsShenzhen’s growth over 25 years to 2007provides a dramatic example of the rate ofurbanisation. Mining products are beingused to build infrastructure and meet thegrowing demands arising from the greaterprosperity in markets like this.

Geological challengesCopper is a good example of the decliningore grade issue. At the start of theindustrial revolution, 200 years ago, minedconcentrations of copper were around17%. Fig 4 shows the recent trend in

2011 population distribution Expenditure per capitaUS$(2011 terms)

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Fig 2. Mineral consumption and polulation distribution (left) Fig 3. Shenzhen (above) in 1982 and 2007

Fig 4. Ore grade decline Fig 5. Copper production energy

Fig 6. Value drivers

Fig 3 Fig 3

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average head grade for copper mineproduction. It can be seen that by the endof this decade copper grades will fall belowone per cent. Therefore nowadays one hasto crush and grind 100 tonnes of rock toliberate one tonne of copper. Not onlydoes this generate a massive quantity ofwaste, or gangue, but the energy usage isvery high. Energy consumption increasesrapidly as the grade falls, as shown by Fig 5,which shows the total energy requirementin kWh per tonne of copper, plottedagainst the ore grade. You can see that itis the comminution or grinding energy thatis impacted by the ore grade, not thesmelting or refining energies, which areconstant.

Important value driversFig 6 shows the important value driversthat are the targets for improvement inmining. With respect to the ore body, valuecomes from improving the recovery forexisting resources, the ability to recover

metal from difficult ore and fromdiscovering new ore bodies. Within theprocess the drivers are removing orminimising waste and improving bothcapital and labour productivity. Labourproductivity is particularly important forremote operations where employee relatedcosts are inflated. Reducing the energyconsumption is another key value driverand new processes provide the opportunityfor step changes here.

Emerging technologiesSo what are the innovative technologiesthat are emerging in mining? Automationand robotics feature very strongly incurrent research and development, alsomechanised rock cutting for undergroundmining, novel mineral recovery andgrinding technology and enhancedsolution mining or leaching.

New and more cost effective sensors willbe essential to creating the Mine of theFuture™. On-line sampling and analysis in

the mine to improve production planningand increase ore body knowledge is ofinterest as are many other applications. Ibelieve that we will see a revolution invisualisation, simulation and predictivemine control. Benefiting from access tothis new data and knowledge will be newways of working through remoteoperations and support centres (orProcessing Excellence Centres in Rio Tintoterminology). For example, Fig 7 shows anunderground mine block cave with CaveTracker sensors, which enable livemonitoring of the ore flow. The sensorswere invented by the CRC Mining anddeveloped by Elexon. Secondly, Rio Tinto’sairborne gravity gradiometer (Fig 8) beingdeveloped for remote exploration. Fig 9shows Rio Tinto’s three dimensional minevisualisation user interface.

Mine of the FutureTM

Launched in 2008, the Mine of theFuture™programme is Rio Tinto’sapproach to generating future value byfinding better ways to mine through newtechnologies. The programme covers manyof the aspects described previously, but thekey themes are achieving massiveproductivity gains in surface mining,recovering more efficiently from complexresources and technologies to access verydeep ore bodies faster.

Autonomy Our iron ore mining operation is very large.Pilbara Iron capacity has expanded to 290million tonnes per year and is aiming for360. Understandably then, the mostadvanced part of the Mine of theFuture™programme is in surface mining.The aim is to develop ways to automatethe mining process and you can see foursurface mining automation examples inFig 10. We have sought to improve theoccupational health and safety of ourworkers, improve the mining process andreduce the environmental footprint.Automation enables improved accuracy

VK1 inside the plane measures thevarying gravitational fields as it flies overdiffferent materials and calculates thegravity gradients. Buried orebodiesbecome visible

orebodyMore dense = higher gravitational field

Host rockLess dense = Lower gravitational field

Fig 7. Cave tracker Fig 8. Gravity gradiometer Fig 9. Mine visualisation

Fig 10. Mining automation examples

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and consistency of mining processes andthe optimisation of operations. Thebenefits from these are stronger driversthan cost savings through labourreduction.

Rio Tinto Iron Ore is commerciallydeploying a Komatsu 290 tonneautonomous haul truck fleet across itsmines in Western Australia and they havemoved about 130 million tonnes ofmaterial so far.

Our autonomous blast-hole drills arebeing rolled out at the West Angelas ironore mine, in the Pilbara, as we speak, andthey have just drilled one million metres ofblast holes.

AutoHaul™, the world's first automatedlong-distance heavy-haul rail network willbe launched this year. One a smaller scale,we are also jointly developing, with LewisAustralia, a robot to change the wheels onhaul trucks and hence eliminate a serioushealth and safety risk.

Automating discrete pieces ofequipment creates value but the realbenefit will come from integration of theseautonomous systems and a holisticapproach to mine management.

Operations CentreAs mentioned, Rio Tinto Iron Ore has anoperations centre. In a purpose-builtbuilding at Perth Airport, it is “MissionControl” for the entire Pilbara network. Werun a complex operation consisting of 14mines, up to 1500km of rail network andthree port terminals, as well as power andother infrastructure. Synchronising andaligning each element is extremely difficult– but crucial. The Operations Centrefeatures more than 200 controllers andschedulers and more than 230 technicalplanning and support staff, who have end-to-end visibility of our value chain,including mobile equipment dispatch,crushing and screening, train loading andrail operations, all in real time, 24 hours aday, 365 days a year.

Processing Excellence CentresA related, but different concept that weare calling the Processing ExcellenceCentre, is also exciting us at Rio Tinto. Notto be confused with our R&D Centres ofExcellence, these will focus on the supportof globally located operations that havesimilar processes. The advances incommunication, collaboration, analyticaltools and models allows collocated groupsof experts to work with operationspersonnel to optimise mining andprocessing outcomes.

The first such Processing ExcellenceCentre, located in Brisbane, supportscopper and coal processing. Thisinnovation will also help mitigate theproblem of attracting and retainingtechnical experts in remote locations.

Minerals sorting and undergroundminingRio Tinto is also developing and testinginnovative sorting and undergroundmining equipment to dramatically improvethese processes. For example, Fig 11shows the Copper NuWave pilot plant atKennecott Utah Copper.

Technology relevanceI have aluminium industry experience andcan reflect upon the applicability of mininginnovations and compare progress. Whilebauxite mining can benefit from many ofthe new developments, the Bayer and Hall-Héroult processes are very mature andhave some unique challenges. So referringto my earlier list, is there any relevance?The answer is yes, in general. Mechanisedrock cutting is an obvious exception.Grinding and leaching advances may haveapplication in alumina production and thetreatment of waste materials, such as redmud remediation. I’d argue that the otherareas are relevant to aluminium productionand indeed are already the subjects ofresearch and development.

RoboticsClearly in aluminium, opportunities forautonomous vehicles exist. Anode andingot stacking are already automated, butanode setting, metal tapping, roddedanode and hot metal transport are obviouscandidates. Perhaps the reason for the lackof commercial application in these areas isthat the payback is insufficient based onreducing operator numbers alone. Butthere are also HSE benefits from reducingoperator exposure, particularly to heat. Infact the greatest benefits will (and must)come from improved accuracy andrepeatability through eliminating manualoperations and from the ability to createmore streamlined, well-coordinated andefficient operations through integration.These benefits are difficult to value.However, work is going on. Autonomousanode setting has been trialled and we areseeing the first applications in smelters. Forexample, Rio Tinto Alcan with the strongsupport of ECL, has an autonomous anodesetting development programme calledBest Anode Change at the Jonquiere AP60plant and one can expect more newsabout this in the future. Autonomous hotmetal transporters have been developedand trialled, for example by CSIRO.

SensorsNew and more cost effective sensors arealso fruitful areas. We know that the

reduction process in particular is poorlymonitored and it resists the application ofnew sensors because of the highlyaggressive environment and the hugenumber that would be required, forrelatively low production intensity. Therewould appear to be many opportunities forinnovative low cost continuous or semi-continuous sensors, for measurements ofkey process variables such as bath andmetal composition and properties, anodeand cathode currents, reduction cell liquidheights, alumina flow rate andcomposition, gas analysis for PFC emissions,and thermal imaging and analysis.

Operations and processingexcellence centres for aluminiumproductionThe availability of large volumes of data,increasing computer power and thevisualisation, simulation and controlpossibilities that they create, are highlyapplicable and will facilitate operationscentres and processing excellence centres.And these are developing. For example, RioTinto Alcan is pursuing both the conceptsof Smelter Operations Centres and RemoteCentralised Process Control Centres. Theformer will use the MESAL IT platform toallow the integrated management ofmultiple processes or even several smeltersfrom one location. The latter aims atcreating regional Alpsys OperationsCentres, or AOCs, to host the expertprocess teams supporting smelters thathave ALPSYS controlled potlines, ALPSYSbeing the Rio Tinto Alcan proprietaryreduction process control system.

So while I cannot offer any earthshattering solutions for the aluminiumindustry, there are similarities betweensome mining and aluminium innovationsand obvious benefits in sharing andcollaboration.

ConclusionMining understands the need to adoptstep change technologies. I believe thatmines of the future will be far moremeasured, automated, integrated, andremotely managed and supported thannow. This will greatly contribute toimprovements in safety, environmentalperformance, productivity and energyefficiency. People will still be essential tomining but many of the traditional roleswill change as a result of new ways ofworking. This will create opportunities.

The ongoing pursuit and support ofinnovation is essential to achieving thisvision. �

Fig 11. Copper NuWave pilot plant

MINING

EXTRUSION - ADVERTORIAL


Reiter & Crippa S.r.l., part of the PEGroup based in Vimercate (Milano, Italy)last January 2014 has signed a contractwith INDINVEST LT of Cisterna di Latinafor the supply of engineering,construction, delivery andcommissioning of a Double chamberStatic Melting Furnace, with capacity70t, to be dedicated to the productionof aluminium alloy billets, having thebest melting performance in terms ofdross formation and fuel consumption.

The furnace features a couple ofregenerative burners in the hot chamberand a dual-type oxy-fuel system in thecold chamber. The melt circulationbetween the two chambers will beperformed by an electromagnetic stirred.

The metal will be poured to the holdingfurnace by a melt transfer pump.

After entering into production in January2015, the Double Chamber StaticMelting Furnace will allow the Customerto improve its flexibility in the charges toto be molten, while keeping the safeststandards in terms of health of theworkplace and emissions to theenvironment.

Reiter & Crippa S.r.l. started up inbusiness in the 60’s dealing in machinesand plants for production of aggregates.Reiter & Crippa S.r.l. started its activity inthe aluminium field 6 years ago when itbecame part of the group PresezziExtrusion S.p.A..

The group recently commissionedequipment in the aluminium field withfull success, like the holding furnace andbillets casting machine at SAPA Tibshelf(England), or the annealing furnace atFramiva Metalli (Italy).

[email protected] www.reiter-crippa.it

- Comprehensive installation services from steel housing to full relining for any size

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TRANSPORT & HANDLING - ADVERTORIAL www.aluminiumtoday.com

The consumption of yoke studs is huge inaluminium production. Today in most plants, therepair process is carried out manually. Thistraditional manual repair cannot be cost effectiveand cannot grant high quality standard, since itimplicates handling and transportation of theanode yoke and it relays on the ability of humanoperator both on welding and the cut, which isusually performed with flame cutting. Flamecutting results in damage to the surface, which isused afterwards for welding, while reduction ofthe electrical resistance of the welded joint is ofmajor importance. This eventually affects the totalcurrent efficiency of the electrolytic process andthe cost of the same.

The Automated Stud Repair LineThe Automated Stud Repair Line (ASRL) from HMRrepairs anode yokes by replacing worn-out studswith the new studs whilst anode yoke and rod ison the powered and free conveyor in the roddingshop. HMR’s repair line is fully automatic andrequires only one operator.

Description of the operationsThe operation starts by testing of every anode studon the anode yoke in accordance with the wearand tear specification set up by the customer.Anode studs with wear and tear above theacceptable limits are processed on the ASRL forreplacing. Powered and free conveyor bringsanode rod forward, first to the cleaning station,then to the cutting station, where a saw cuts theexhausted stud from the yoke, and finally into thewelding station, where fully programmablewelding robots perform a perfect welding.After the replacement of worn anode studs theanode yoke with rod is returned to the roddingshop.

By Italo Dal Porto*

station. While one robot handles the new stud,checks and prepares it for a correct replacementand welding, the other two robots executewelding operation simultaneously from both sides.Ready repaired anode yoke and rod is returnedinto the system for rodding.

Safety systemThe whole of HMR’s ASRL is surrounded by asafety fence. Each robots station has additionalsafety fence. In case of door opening, the systemstops robot movements momentarily.

Performance, capacity and qualityHMR’s ASRL brings the studs distinctively to thesame condition as on the new anode yoke. Theoperation provided by ASRL results in a lowelectrical resistance of the joint owing tooptimized cutting and welding proceduresdeveloped by HMR and executed repeatedly by theautomated robotic line.The system has a repeatability of < 0,1 mm (NB.depending of anode rod condition) and aproductive capacity of 6 min. (NB. depends ofgroove welds design, number of studs per anoderod and a conveyor speed). The welding time isabout 4 min per stud.It’s quite important that the cutting and weldingarea is clean for bath, rust and iron scale. That iswhy a chain centrifugal blast cleaning is a part ofthe ASRL system. This device prevents bath, rustand iron scale to interfere with welding and itelongates lifetime of saw blades (40% aluminacontents in bath is very destructive to saw blades).It effects in up to 800 - 1000 studs cut obtainedfrom recommended saw blades. However one must bear on mind that quality ofweld provided by ASRL depends also uponexternal conditions. The most important forexample is that joint surfaces are clean andmachined. The studs cut by saw have a bright steelsurface, which is preferred for welding.

*Senior Engineer in HMR Hydeq AS

HMR’s automated stud repair line

During the process of cleaning of studs for bath,rust, oxide scale, etc. some dust is released. Alsoduring the welding process, welding gas appears.In order to effectively contain these impurities, aspecial cyclone filter has been installed on ASRL.

Advantages of HMR’s ASRLThe line is completely automated and requires justone supervising operator. The process is efficientand very safe for the floor personnel. It reducesrepair downtime to the minimum. There is noneed for removal of anode rods out of theconveyor during replacement. Fewer anode rodsare used in the plant (estimation 2 - 4%). Studs arereplaced exactly according to the procedure set upby the customer.

Measuring stationAll complete anode yokes and rods aretransported on power and free conveyer to HMR’sASRL measuring station. Each anode stud ischecked against wear and tear limit set up by theCustomer. Anode studs with the acceptable wearand tear level are returned to the plant operation.The measurement station collects historical data,which later can be used for statistical purposes.

Cleaning stationThe HMR’s ASRL system sends a signal to the robotoperated cleaning device and indicates which studis to be cleaned. The robot with chain centrifugalblast cleaning device starts to clean sawcutting/welding area.

SawThereafter the anode yoke and rod is transported

to the automatic saw station. Data from themeasuring station is transferred to the cuttingstation, which performs cutting according tothe obtained information.

Welding stationAfter removal of a stud or studs, the anode

yoke and rod is directed to the automatic welding

The specimens show the homogeneous welding

attainable and how tight the two parts are pressed

together. This improves the electric conductivity and

transfers heat better then than other joints available on

the market today

HMR’s ASRL brings the studs distinctively to the same condition as on the new anode yoke.

www.hmr.no

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HMR Group AS, Prestnesvegen 68, N-5460 Husnes, Norway, e-mail: [email protected], website: www.hmr.no

AUTOMATED STUD REPAIR LINEFocus on the Rodding Shop

Automated Stud Repair Line repairs anode yokes by replacing of worn-out studs with the new pins whilst on the power and free conveyer in the rodding shop.

• The operation consists of cleaning, cutting and robot welding of pins;

• Completely automated. Requires just one supervising operator;

• Efficient, very safe for the floor personnel. Reduces repair down-time to the minimum.

This line has been developed by HMR. HMR’s technology for the smelters has been the reference in the primary aluminium since 1956. HMR is situated in Norway, with the customers all over the world.

To stay tuned to the world of modern solution for the rodding shop, meet HMR at 6th International Conference on Electrodes for Primary Aluminium Smelters in Reykjavik, Iceland, 13-15 May 2014.

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25www.aluminiumtoday.com FURNACES/HEAT TREATMENT


Forced circulation in an aluminium meltingfurnace can markedly improve furnaceperformance. The advantages that acirculation system will provide, dependingon the furnace and process type, include:� Reduced furnace energy consumption(10–20%)� Improved melt rate/productivity(10–50%)� Reduced melt loss � Improved furnace temperaturehomogeneity� Improved furnace chemicalhomogeneity

Even with modern furnaces, onlyapproximately 40% of the heat energy istransferred to the aluminium bath; heatloss through the flue can range from 35-50% with the remaining heat loss beingconductive.

Radiant heat transfer from thecombustion system and hot refractorywalls provide 80-90% of the heattransferred to the bath surface. The

remaining heat is transferred through lessefficient conductive and convective heattransfer.

Molten aluminium has a thermalconductivity about 50% lower than solidaluminium; the bath surface becomes evenless thermally conductive as it becomeshotter.

When melting solid aluminium atambient temperature to about 749°C(1380°F), 55% of the energy is absorbedbefore the melting point. An additional30% of the energy is absorbed as thealuminium changes phase from a solid toa liquid (latent heat of fusion). This means85-90% of the energy is transferred to themetal while it is still in solid form andpotentially submerged beneath the bath.

Without forced circulationIf not circulated, energy movement fromthe bath surface to the submerged solids isreduced; the melt rate becomes dependenton less efficient conductive heat transferfrom the bath surface to submerged solid

charge material.Bath temperature variation top to

bottom can vary by approximately 60-70°C (140-160°F) in a typical furnace.

With proper forced circulationBath circulation ensures that the region ofthe bath surface that receives highintensity heat flux constantly moves,making sure the molten bath does not getexposed to excessive heat for prolongedperiods of time.

The lower depths of the molten bathconstantly move, which aid in thedissipation of the heat, preventingexcessive heat accumulation at the bathsurface and more efficient heat transferthroughout bath depth and to thesubmerged solids.

If a 100% energy transfer were possible,it would take 1128 kilojoules per kilogram(485 British thermal units per pound) tomelt 454 grams (1 pound) of aluminium.For a hypothetical furnace that is only 32%efficient, the energy consumption would

Forced circulation can improvefurnace performance and efficiencyBy Jim Grayson*

*MCR Systems Sales Manager, Pyrotek Inc

26 FURNACES/HEAT TREATMENT www.aluminiumtoday.com


be 2326-3489 kilojoules per kilogram(1000-1500 British thermal units perpound).

Optimum circulation includes turningover the molten metal 7-10 times an hour.Turnover is defined as the number of timeseach kilogram or pound of aluminium inthe furnace passes through the pump eachhour.

Pyrotek offers a molten-metal circulationsystem for almost any type of furnace,including dry hearth, which typically drainscompletely each heat, twin-chamber oropen side well, which normally operatewith a molten metal heel. Furnace designsinclude both stationary and tiltingfurnaces.

Pyrotek’s Metaullics operations in theUSA and Europe provide state-of-the-artmechanical circulation and transfer pumpsin conjunction with the LOTUSS vortex. Inaddition, the Metaullics systems can offera variety of options, including gasinjection, metal transfer and smart-pumptechnology.

The Pyrotek electromagnetic pumping(EMP) system provides an effective solutionfor circulating the furnace bath whileallowing scrap and other additions to becharged into the LOTUSS vortex forefficient delivery and optimum yield oflight-gauge scrap and alloying elements.The EMP can also provide an effectivemolten metal transfer option. The EMP

system can be applied to most furnacetypes and is easily attached to mostexisting furnace types.

EMP’s new under floor stirring system(UFS) with a unique patent-pending coildesign provides consistent circulation for arange of aluminium furnace sizes. This newaddition to the product line was developedby the EMP engineering team at Burton onTrent, UK. This system is positionedunderneath the furnace, which requiressuitable access by either a tilting design ora basement. A partial replacement of thefurnace steel floor shell to stainless steel isrequired. The UFS can also be suppliedwith a shuttle system to enable multiplefurnaces to be treated by a single UFS unit.By using a modified low-frequencyelectromagnetic current, we are able totransfer the electromagnetic current

through the furnace floor refractory andmove the molten aluminium in thefurnace. For example, the UFS 300 canmove 300 tonnes of molten metal perhour to provide a 35-tonne furnace aturnover of 8.5 times per hour.

The company’s new developmental,patent-pending heated launder pump(HLP), combines the effectiveness of EMPcirculation with Pyrotek’s heated laundersystem. This system was specificallydesigned for those customers who do notneed a LOTUSS system for scrapsubmergence. When operated in furnacecirculation mode, the system pulls themetal from the bath through the laundersystem, minimizing turbulence and drossbuild up while providing optimum massflow and velocity. It features a series ofdross dams and the ability to measure thetemperature and bath level in the launder.This system will also provide metal transferoptions, as well as gas injection and theaddition of refining agents such asPROMAG.

Pyrotek’s global network of technicalspecialists work with customers todetermine which circulation system willbest suit their applications and ensureoptimum furnace efficiency and maximumreturn on investment. �

Contactwww.pyrotek.info/emp

LOTUSS: Low Turbulence ScrapSubmersion SystemQ. Is refractory wear accelerated bythe ‘whirlpool’ motion?

A. There is very little erosion in theLOTUSS. The bottom shape can bereplaced and with normal operation thebottom shape is replaced each 2-3 years,depending on the type of operation.

Q. What is a typical feed rate?A. This depends on the density of scrap

being charged and the melt rate of thefurnace - on light gauge scrap types suchas UBC with densities of approx. 15 lbs percubic ft. (240 kg/m3), the submersion rateis 10 metric tonnes per hour. Heaviergauge scrap can be charged at ratestypically up to 15 metric tonnes per hour.

Q. Is it suitable for adding additionsof volatile or reactive (eg Mg) alloys?

A. Our customers do charge Mg in theEMP LOTUSS – care must be taken that thematerial is dry and the ingot size does notdamage the refractory shape in the bottom– other volatile or reactive elements wouldneed further evaluation depending on thespecific element and process. Ourcustomers do alloy elements such as Cu, SI,

Mn, Fe, etc. This is beneficial; as the alloyscan be added to the furnace while thedoor to the main chamber is closed andthe furnace is melting, the alloyingelements are dissolved quickly and elementyield is improved. In addition, the chemicalsamples can be taken from the EMPLOTUSS, due to the powerful circulationthese samples are representative of theentire furnace bath.

Under Floor Stirring SystemQ. What is the power requirement(in kWh)?

A. Nominal 80-90 KwH

Q. How does that compare with amechanical pump system?

A. The UFS mounts under the furnacefloor. The mechanical pump systems aremostly on furnaces without accessunderneath and dual chamber furnaces.These furnaces have an open side well. Hotmetal is pumped from the main furnacechamber and circulates through the sidecharging well and back into the mainfurnace chamber. Scrap is charged into theopen side well. These furnace types areexcellent for charging light gauge scraptypes.

Q. How does maintenance comparewith a mechanical pump?

A. There is very little maintenance forUFS. This is not a fair comparison as theprocess for a UFS and a mechanical pumpare completely different.

Q. Can it be fitted as a retrofit? A. The UFS can be a retro fit as long as

there is access underneath the furnace, i.e.a tilting furnace or basement.

Q. Typical cost of modifying afurnace to install the stainless steel‘window’?

A. (This has to be an austenitic [non-magnetic] panel of steel in the bottom ofthe furnace. The furnace would then belined with refractory in the normal way.)This would depend on many things:Furnace type, refractory age, process type,etc.

Q. Is there any potential to use theEMS principal in the DC castermould to reduce segregation whencasting alloys?

A. No, they are two completely differentprocesses.

Question & Answer

Molten Metal Level Controletlt taeMen tteloM veevel ControlveLtal

Swarf dryers

is an

group company

28 FURNACES/HEAT TREATMENT www.aluminiumtoday.com


Faced with today’s tough economicconditions, aluminium plants acrossEurope are looking for better ways toprocess low-grade scrap metal. It makesgood financial sense, but it also presentsmany challenges.

Low-grade scrap metal is oftencontaminated with oil, paint and plasticand this is where the problems emerge.Heavy fumes, flames and post-combustionoutside of the furnace cause hightemperatures in the ducting system andinfluence baghouse operation, efficiencyand emissions.

Air Products has developed a newgeneration oxy-fuel melting technology,which consists of two main features – aHigh Yield Oxy-Fuel Burner and anAdvanced Low Emission Melting controlsystem (ALEM), which can be tailored tospecific melting requirements for increasedflexibility. The aim is to enable theprocessing of highly contaminated scrap,minimise melt losses, and flux usage whilstalso increasing productivity by reducingcosts and total emissions. The ALEMsystem measures the degree ofcontamination, automatically controllingthe oxygen flow to ensure more efficientcombustion. As a result, combustion iscontained within the furnace where theextra heat generated can be used formelting, reducing energy costs andshortening the cycle time.

The High-Yield Oxy-Fuel Burner isdesigned to provide the same benefits asconventional oxy-fuel technology – fuelsavings, increased production and reducedbaghouse temperatures and loadings.Additionally, comparable testing withconventional oxy-fuel burners has proventhat, with the high-yield burner, flux isreduced by 10-15% and yield is furtherincreased by 1-2%.

The new melting technology alsoprovides savings through reduced melttimes and excess air, protective furnaceflow patterns and a more consistentoperation, when compared to air-fuelsystems. An added advantage is that thetechnology can easily be retro-fitted toexisting air and oxy-fuel operations withminimal interruption to productionschedules.

Case studyFor many years Air Products has workedwith REMET Spol s.r.o., one of the largestproducers of aluminium casting alloys inthe Czech Republic, to help improve itsmelting technologies on rotary and reverbfurnaces.

The company has been using AirProducts’ new melting technology sinceearly 2012 and production manager MrLudek Septun is pleased with the results:“We’ve measured a positive impact to yieldand, with the combination of further

melting control optimisation such as withthe ALEM technology, we’ve achievedgreat results in production, yield and lowermaintenance on the ducting andbaghouse system.”

REMET has experience in processing low-grade scrap. “In the last few years we havestarted to improve our operations in termsof controlling the combustion process. Thenew ALEM advanced control systemdesigned by Air Products has broughtmany hard and soft advantages – one ofwhich being an enhanced ability to processa higher percentage of contaminated scrapmaterial than before,” continued MrSeptun.

“The installation and implementationwas initially carried out by Air Products’trained experts, including training of ourown operators. Following the successfulinstallation, the system needed to be tunedto our specific operating conditions - a veryimportant part of the set-up process. Theinitial settings were set by Air Products andthen, working together over the followingweeks, we optimised the systemfunctionality with online data and handson experience from our facility operators.With the results we’ve experienced, wenow operate this new burner andadvanced control system on two of ourrotary furnaces, where we continue torealise real financial and operationalbenefits.” �

New burner technology:Turning low-grade scrap metal into

high-efficiency savingsPetr Tlamicha* explores how aluminium processors can overcome some of the issues associated with

low quality secondary material.

*Industry Manager for Primary Metals and Minerals, Air Products.

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At Sunndal in Norway, Hycast, a fully-owned subsidiary of Hydro Aluminium, hasbeen developing casthouse technologysolutions for Hydro since 1990. Recently,the company started offering its productsto external customers. The LPC technologyfor extrusion billet casting is one of severalgame changing technologies launched byHycast.

The last few years have been tough onthe casthouse technology business, withrelatively few new investments to competefor. The difficult environment made itnecessary for Hycast to reduce manning bynearly 25% and to re-think the valueproposition of Hycast. But things arelooking up and Hycast are now receivingmore and more external orders.

Also Rio Tinto’s ISAL smelter in Iceland iscurrently on Hycast’s customer list, havingordered a full casthouse equipment setupfrom the company, excluding melting andhomogenisation furnaces. Further projectsin China have been signed in recentmonths where Hycast will providecomplete casting lines including laundersystem, inline melt treatment, vertical DCcasting machines with moulds tables andcontrol system.

Instead of having to install several filtersbetween the melting furnace and thecasting table, the SIR filter refinesimpurities and hydrogen from the metal inone fully automated operation. Thus thebenefits for the producers include shortertime for resetting a cast, fewer filters toclean and maintain, as well as benchmarkenvironmental performance.

There are two more key technologiesfrom Hycast: � The Low Pressure Casting (LPC)technology, which will be installed shortlyin two casting lines in China. � The Adjustable Flexible Molds (AFM)casting tables, currently being installed atHydro’s sheet ingot casthouse in Høyanger,Norway.

With the AFM technology, the producersare able to reduce the needed cut-off atthe end of the slab because the technologyenables casting of slabs with virtually noconvexity. In addition, the casting tablesare adjustable so that instead of having topurchase a casting table for eachdimension, producers only need one table.That reduces their investment andmaintenance cost significantly.

LPC technology is based on the gascushion, direct chill, casting technology,which Hydro has been utilising in itscasthouses for more than two decades.LPC gives a more consistent surface quality

and improved extrudability, ideal forproduction of larger diameters and hardalloys. This technology is the topic of thisarticle and will be explained below.

LPC technologyWhen surface quality mattersIn 1977 Showa Denko filed a patent on anew hot-top casting technology forextrusion billets where gas (air) wasintroduced into the mould, [Mitamura1977] [Mitamura 1978]. This new castingsystem produced billets with a reducedsegregation zone and an improved surfacequality compared to the traditional spoutand float system based on open moulds orthe hot-top moulds used in the casthousesat that time. In 1984 Wagstaff published avariant of this technology where the gaswas introduced through a graphite ring,

giving further improvements in surfacequality, [Faunce 1984]. Some years laterHydro filed a patent based on the Showaconcept but here oil and gas wasintroduced in separate graphite rings. Thistechnology is named Gas-Cushion (GC),[Steen 1997].

After the innovations mentioned aboveno real step change in surface quality hasbeen published on extrusion billet casting.This article describes a new castingtechnology developed to give a smoothersurface with less surface segregationcompared to the air (gas) assisted mouldswith graphite mould wall. This technologyis named Low Pressure Casting (LPC); seeFig 1 for an example of billets producedwith this technology.

The surface segregation zone includingthe depleted zone normally found just

33


By Arild Håkonsen*

*Head of Technology Management, Hycast AS

Aiming to change the casthouse game

www.aluminiumtoday.com CASTHOUSE

Fig 1. Ø405mm (16”) LPC billets just after casting, AA6060 alloy

inside of the enriched zone at the surfacemay cause problems in the downstreamhomogenisation and extrusion process ofthe extrusion billets. This may be related tolocal melting of the enriched layer oraesthetic effects on the finished productdue to chemistry differences [Reiso 2012].

For hard alloys the common practice is tomachine off the outer surface of the billetsprior to extrusion by turning or peeling.This is because these billets normally havevery severe surface segregation due to thecasting technology used for these alloys(normally hot-top mould with no gas).

TechnologyThe basic idea of the Low Pressure Catstin(LPC) technology is to avoid metallostaticpressure in the mould cavity, and thus

eliminating the driving force for exudation.Extrusion billets are today produced in asemi-continuous DC casting process withcasting tables with up to 160 moulds,[Steen 2011]. It is vital to have an even andcontrolled feeding to all moulds and tohave a controlled process. The LPC processensures an accurate metal level control inall moulds utilising only one control damand one laser.

Fig 2 shows the LPC principle. To ensurefeeding to each mould the LPC technologyutilises siphon filling to each mould byapplying a under-pressure in the basinabove the moulds. An ejector is used togenerate and control the under-pressure sothat the position of the metal in the basinis stable during casting.

The mould is ventilated towards the

casthouse atmosphere. This ensures thatthe pressure above the metal in the mouldcavity is the same as the pressure on theouter surface of the billet below the air gapposition – the point at which the billetmoves away from the mould wall and anair gap forms between the billet and themould. In this way there is no driving forcefor exudation since the pressure in theresidual melt between the grains justbelow the air gap is virtually the same asthe air pressure outside the billet surface.In addition the LPC concept with ventilatedmoulds will give a stable meniscus in themould without any pulsation.

The mould height is defined by the metallevel in the distribution launder, which iscontrolled within ±1mm using a laser anda control dam. The LPC principle thus

34 CASTHOUSE www.aluminiumtoday.com


Vacuum EjectorDistribution launder

Lid seal

Ejector

Casting tablecabinet

Distributionbasin

Casting unit lid

Thermocouples

Venting

Fig 2. The basic principle of LPC casting

Fig 3. A typical layout of an industrial LPC casting table

Fig 4. (left) LPC table inproduction

120

1200

Conventionalhot-top

Gas assistedmould GC

LPC

1000

800

600

400

200

00 50 100

Diameter (mm)

150 200 250 300 350 400 450 500

Inve

rse

segr

egat

ion

zone

, ISZ

(μm

)

100

80

60

40

20

00New

technology(LPC)

ConventionalTechnology

(CG)

5 10 15 20 25 30

Thic

knes

s of

sur

face

seg

rega

tion

zone

(μm

)Pressure in melt (mbar)

35 40 45 50

Fig 6. (left) The effect ofdiameter and castingtechnology on the widthof the inverse segregationzone for AA6060 typealloys

Fig 5. (right) Therelationship between themetallostatic pressure inthe mould cavity and thewidth of the inversesegregation zone.Diameter Ø203mm (8”),alloy AA6060

Ingot surface

Hot

-top

/Gas

-cus

hion

tech

nolo

gyLo

w p

ress

ure

cast

ing

tech

nolo

gy

Microstructure - surface

Fig 7. (right) A comparisonbetween the surfacequality between a GC andLPC billet. The diameterwas Ø203mm (8”) and thealloy was AA6082

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makes it possible to use different mouldheight for different alloys in the samecasting mould. It is also possible to changemould height during casting at differentstages of casting.

Fig 3 shows a typical industrial setupwith 48 moulds. The lids on the castingtable are there to be able to apply anunder-pressure in the basin during casting.The casting table and the starter block andmoulds are based on the well-provenHycast GC Billet Casting System but somemodifications have been made to be ableto use the LPC principle. Fig 4 shows a LPCtable in production.

The LPC technology is protected by twopatents, [Ånesbug 2003] [Fagerlie 2007].

Results6xxx alloysFig 5 is a presentation of severalexperiments where the metallostaticpressure is varied and the resulting widthof the inverse segregation zone (ISZ) ismeasured. The dimension is Ø203mm (8”)and the alloy is AA6060. These results arepartly from GC and partly LPC billets. Thewidth of the ISZ is increasing with themetallostatic pressure. For zerometallostatic pressure in the mould cavity,corresponding to LPC, the width of the ISZis only ¼ of the width for conventionalcast billets which typically has a metal headof ~150mm (35mbar).

Fig 6 is a comparison between thewidth of the inverse segregation zone inLPC billets for varying diameters comparedto results for conventional gas assistedmoulds and hot-top moulds. The width ofthe ISZ was measured using a lightmicroscope. An average thickness of thezone for several measurements in thecasting direction were used.

Fig 7 is a comparison between the castsurface quality of a billet cast and the GCand the LPC technology respectively. Forthe GC billet we can clearly see exudatedmaterial and clear ring formation. Thewidth of the zone with surface segregationis also clearly visible in the sub surface

micrograph in Fig 7. For the LPC billet therings are almost eliminated due to the lackof pulsation of the gas pocket, and noexudation can be seen.

The surface segregation was alsoquantified using multiple line scans inSEM. Fig 8 shows results for two billets,GC and LPC of diameter Ø203mm andAA6060. These results show not only athinner ISZ for the LPC billet than the GC,but also a much leaner zone, with achemical composition much closer to thebulk material compared to the GC billet.

Hard alloysSeveral trial castings with LPC and hardalloys were performed in a Ø152mm (6”)



4,00

Mg Mg

Si Si

Mn Mn

Fe Fe

3,50

3,00

2,50

2,00

1,50

1,00

0,50 0,50

0,000,00

0 0 50 50100 100

Distance from billet surface [μm] Distance from billet surface [μm]

LPC not homogenised

150 150200 200250 250300 300

Allo

y co

nten

t [w

t%]

Allo

y co

nten

t [w

t%]

GC not homogenised4,00

3,50

3,00

2,50

2,00

1,50

1,00

Fig 8. A comparison between the surface segregation pattern for a LPC billet (left) and a GC billet (right). Both billets were of diameter Ø203mm (8”) and alloy AA6060

Fig 9. AA2024 billets cast with the LPC casting technology

Fig 10. AA2024 billet sub surface micro structure

8

7

6

5

4

3

2

1

0

0 200 400 600 800 1000

Cu

ISZ-profile of ch77096 AA2024

Distance from surface [μm]

Mg

Mn

Fe

Si

Wei

ght

%

Fig 11. The surface segregation pattern in a AA2024 billet

Fig 12. AA707 billets cast with the LPC casting technology

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casting table. Fig 9 shows the very smoothas cast surface of the AA2024 billets. Fig10 shows the sub surface structure of thesame alloy. No surface segregation couldbe seen in light microscope for this alloy.

The segregation pattern wereinvestigated in the SEM, see Fig 11. Basedon these results the width of the ISZ wasless than 100μm and the chemicalvariations were very limited.

Fig 12 shows some billets of alloyAA7075 cast with LPC. The same smoothsurface as for AA2024 can be seen in thesebillets. Fig 13 and 14 shows the subsurface micro structure and segregationpattern respectively.

Verification/validationThe LPC technology is verified for a widerange of alloys (both soft and hard alloys)and for diameters ranging from Ø150mm(6”) up to Ø735mm (29”) (Fig 15).

Operational experience is gained fromregular operation in two casthouses. Theachieved pit-recovery and cycle time wascomparable with typical values for theHycast GC Billet Casting System.

DiscussionFor soft alloys the reduction in surface

segregation may make it possible toextrude more of the billet until back flowof the segregated layer into the profile.This may reduce the necessary butt endlength. If inflow of segregated material islimiting the extrusion in any other way athinner and less enriched zone may giveincreased extrusion speed and/or less scrapin the extrusion plant.

The common practice for extrusionbillets made from hard alloy is to machineoff the outer surface prior to extrusion. Ifthe thickness of the segregated layer couldbe reduced for these alloys this will give apotential of less scraped material, or eveneliminate the need for machining of thebillets completely.

ConclusionsA new DC casting technology has beendeveloped for extrusion billets. This newtechnology is named Low Pressure Casting(LPC) and is characterized by siphon fillingto all moulds, zero metallostatic pressurein the mould cavity and a ventilated mouldto the casthouse atmosphere.

The surface quality of the billetsproduced with the LPC technology issuperior to conventional technologies. LPCgives a smoother surface and less enriched

and thinner surface segregation than otheravailable casting technologies.

Unlike gas assisted moulds used todaythe LPC technology seems to be well suitedfor producing hard alloys. Excellent surfacequality is demonstrated for alloys such asAA2024 and AA7075 with inversesegregation zones less than 100μm.

The LPC technology is verified for a widerange of alloys and diameters, andvalidated in regular operation. �

AcknowledgementThe authors would like to acknowledge allthe skilled people that during the lastdecade have been involved in thedevelopment of the LPC technology. BjarneHeggset, Geir Ånesbug, Torstein Sæther,Bjørn Vaagland, Sverre Hanaset, Idar Steen,Steinar Benum, John Olav Fagerlie, DanielSjølset the Hydro Reference Centre crewand many more.

References[Emely 1976] E. E. Emily, “Continuous casting ofaluminium”, International Metals Reviews, Review 206,1976, pp. 75-115.[Fagerlie 2007] Patent US8413711[Faunce 1984] J. P. Faunce, F. E. Wagstaff and H. Shaw,"New casting method for improving billett quality", LightMetals, 1984, pp.1145-1158[Mitamura 1977] Patent US 4157728, “Process fordirect chill casting of metals”[Mitamura 1978] R. Mitamura et. Al, "New Hot-topContinuous Casting Method Featuring Application of AirPressure to Mold", Light Metals, 1978, pp.281-292.[Mo 1993] A. Mo et al., "Mathematical modelling ofsurface segregation in aluminium DC casting caused byexudation", International Journal of Heat and MassTransfer, Vol 36(18), 1993, pp. 4335-4340[Reiso 2012] O. Reiso, "Flow of Billet Surface Materialduring Extrusion of Al Alloys; Effect of Billet Quality andProcess Conditions", International Extrusion TechnologySeminar & Exposition", 2012, pp.33-47.[Steen 1997] Patent US 5678623, “Casting Equipment”[Steen 2011] I. Steen and A. Håkonsen, “Hycast TM GasCushion (GC) Billet Casting System”, Light Metals 2011,pp[Ånesbug 2003] Patent US20060219378

8

7

6

5

4

3

2

1

00 200 400 600 800 1000

Cu

Zn

Mg

ISZ-profile of ch77227 AA7075

Distance from surface [μm]

Fe

Cr

Wei

ght

%

Fig 13. AA7075 billet sub surface micro structure Fig 14. The surface segregation pattern in a AA7075 billet

Fig 15. A Ø735mm (29”)billet produced with theLPC technology



Emirates Global Aluminium (EGA) – thejointly-held, equal-ownership companyformed by Mubadala DevelopmentCompany of Abu Dhabi and theInvestment Corporation of Dubai, is builton the legacy of EGA’s core operatingentities – Dubai Aluminium PJSC (DUBAL)and Emirates Aluminium PJSC (EMAL) –which have consciously nurturedexcellence-based partnerships withcustomers across the world and beenrewarded with loyal, long-standing tradingrelationships.

Together, DUBAL (Jebel Ali Operations)and EMAL (Al Taweelah Operations) havemore than 40 years’ experience in theprimary aluminium sector. The two sites’combined production in 2013 amountedto 1.86 million tonnes of metal (2012:1.84 million tonnes), representing 50% ofthe total primary aluminium productioncapacity of the Gulf Cooperation Council(GCC). With the completion of EMAL’sPhase II expansion project scheduled forthe second half of 2014, the total annualproduction capacity will reach 2.4 milliontonnes (increasing through creep to 2.5

million tonnes from 2015 onwards) –which will make EGA one of the top fivealuminium producers by volume in theworld (outside China).

Since inception, at least 88% of DUBALand EMAL’s production has been exportedeach year, destined largely for marketsworldwide that are short on primaryaluminium production, but long ondownstream production capacity. Theentire annual production is pre-sold theprior year, primarily to end-users, such thatthe UAE primary aluminium industry hasavoided supplying material into LMEwarehouses. More than 350 customers areserved in more than 64 countriesworldwide, predominantly in Asia, Europe,the Middle East North Africa (MENA)region and the Americas. Reflecting theinherent flexibility of DUBAL and EMAL’scasting facilities, the mix has changed onoccasions to suit both changing marketdemands and global economic dynamics.

By strategic design, more than 90% ofEGA’s annual production comprises value-added products – specifically billet (two-thirds) and foundry alloy (one-third). This

mix has been sustained despite the recentglobal recession, mainly due toinvestments in a range of productcapabilities at the Jebel Ali and Al Taweelahsites that has provided the flexibilityneeded to sustain order volumes. Forexample, the portfolio of extrusion billetshas evolved from a smaller range ofproducts into a more extensive range thatincludes larger diameters, and moresophisticated alloys to cater for evolvingmarket developments in the transport,construction and engineering industries.Moreover, the absolute volume of value-added products and market-share hasincreased steadily over time. Continuousinvestments in technology, together withever-increasing knowledge and expertise,have contributed to strong and enduringpartnership-based relationships withcustomers – which in turn have reinforcedthe positive trends.

The product portfolio of DUBAL andEMAL is shown in Table 1. Bothoperations produce high added valuepurity metal for use in industries such aselectronics and aerospace, extrusion billet

EGA: Casthouse investments to support regional downstream industry

Fig 2a and b (below) Proportional downstream aluminium production in the GCC (2012vs. 2015). Source: Special report by McKinsey & Company

High purity sow and ingot High purity sow and ingot

Billet Billet

Foundry alloy Foundry alloy

Busbar and anode bar

Sheet ingot

DUBAL (Jebel Ali Operations) EMAL (Al Taweelah Operations)

Table 1 Product mix at DUBAL and EMALFig 1 (left) Proportional production, UAEvs. global aluminium industry (2014)Source of global information: CRU

100%

500 700

600

500

400

300

200

100

0

2012

Fig 2a Fig 2b

400

300

200

100

0Bahrain BahrainUAE UAEOman OmanKuwait KuwaitQatar Qatar

2015

Cast

Extruded

Rolled

Wire rod

SaudiArabia

SaudiArabia

80%

60%

40%

20%

0%

UAE

Remelt ingot Foundry alloy Extrusion billet

World ex China Total



and foundry alloy. Billets are produced in a wide range ofdiameters and alloys; while foundry and high purity products aremade in different shapes and sizes according to market needs.The key differences between the two sites are that only DUBALproduces busbar and anode bars, while EMAL produces sheetingot for the leading aluminium rolling companies of the world.EMAL will also deliver molten metal to nearby customers in theemerging aluminium hub at Al Taweelah.

The proportional production of EGA’s main product typescompared to the rest of the industry is shown in Fig 1. In thelatter, remelt ingot accounts for over 70%, with extrusion billetbelow 20% and foundry alloy even less. At EGA, however, billetsaccount for about 60% of annual production, with foundry alloysat approximately 30% and re-melt ingots around 10%. Thisreflect the UAE’s position as one of the world’s leading producersof both billet and foundry alloy.

The predominance of billet in DUBAL and EMAL’s productionmix also reflects the trends in the local and GCC region, wherethe downstream industry has been largely extrusion focused – inturn a reflection of the prevalence of infrastructure developmentactivities. Most regional downstream companies’ products haveremained at the lower-end of the technology spectrum. Today,however, this is changing. A small number of GCC extruders havemoved up the added value chain and now supply a range ofsophisticated products into major markets. There is greatpotential for this trend to continue growing, but technologytransfer will be required along with increased investment in R&Dfacilities.

Recent investment in high volume rolling mills as part of theregion’s economic diversification initiatives is significantlychanging the GCC downstream product mix. Naturally, thegrowth in the downstream industry will be accompanied bysubstantial job creation. Bahrain was the first to invest in rollingwith Garmco and has been a significant exporter of rolledproducts for many years. As shown in Fig 2, Saudi Arabia is setto become the largest downstream player in the GCC within thenext few years, with a forecast capacity of 695,000 tonnes peryear in 2015 – the major growth contributor being a 400,000tonne rolling mill. Saudi Arabia has the largest market in the GCCand the majority of the rolling capacity will offset imports into theregion.

EGA, through DUBAL and EMAL, is equipped to meet thespecific and changing demands of the growing GCC downstreamindustry, as indicated in the product mix forecast from 2015onwards illustrated in Fig 3. This follows the above-mentionedinvestments in the casthouse facilities at both sites, including thecapacity to transport liquid metal to downstream operations inthe vicinity of the EMAL smelter. �

3,000,000

2,500,000

2,000,000

1,500,000

1,000,000

500,000

240,000

780,0001,100,000

380,000

2,500,000

0

Pure metal Foundry Billet Slab Grand total

2015+

Fig 3. Proportional product mix at EGA, 2015 onwards



Aluminium alloys have been gainingincreased acceptance as structuralmaterials in the automotive andaeronautical industries, mainly due to theirlightweight, good formability andcorrosion resistance. However,improvement of mechanical properties isconstant in research activities, either by thedevelopment of new alloys or bymicrostructure manipulation.

The aluminium foundry industry haveacquired know-how to supply mentioneddemanding markets, and it is able toproduce high structural quality aluminiumbased components, by sand, ceramic, diecasting or DC casting processes. However,the strict environmental protectionregulations, and the increasing costs ofraw materials and energy, associated to theincreasing advances of emergent countries,expose aluminium industrial activity toenormous risks and strongcompetitiveness[1]. Thus, the currentchallenges that the aluminium foundryindustry is facing, requires thedevelopment of new manufacturingtechniques with high-tech alloysprocessing parts in order to fulfil the needsof the markets at competitive cost. Thedevelopment of casting techniques willsurely have a positive impact over the life-cycle cost, both in what concerns finalproducts, manufacturing tools andequipment[1]. Moreover, techniques mustfocus on decreasing the environmentalimpact of the activity itself, either byreducing the quantity of raw materials, or

increasing the process yield and reducingenergy costs.

High intensity ultrasound applied tonon-ferrous alloys melt processingUltrasonic degassing/refinement/modifica-tion focus on an effective dynamicmethodology for degassing metallic meltsand to perform microstructural refinementand modification of light alloys, namelyaluminium alloys, by applying ultrasonicvibrations after melting and duringsolidification. This technique improves themechanical properties of those alloys,avoiding the use of traditional chemicalbased degassing and refiningmethodologies, which are less effectiveand present environmental impact.

Ultrasonic vibrations are proven to beeffective in degassing, controllingcolumnar dendritic structure, reducing thesize of equiaxed grains and, under someconditions, producing globular non-dendritic grains, and modifying theeutectic silicon cells in Al-Si alloys. Theinfluence of high intensity ultrasonicvibrations on the microstructuralrefinement is based on the physicalphenomena – cavitation, arising out ofhigh-intensity ultrasound propagationthrough a liquid[2].

CavitationWhen a liquid metal is submitted to highintensity ultrasonic vibrations, thealternating pressure above the cavitationthreshold creates numerous low-pressure

cavities in a liquid metal, promoting twoeffects:(1) Degassing effect: The cavitationachieved by application of ultrasonicvibrations intensifies mass transferprocesses and accelerates the diffusion ofhydrogen from the melt to the developedbubbles. As acoustic cavitation progresseswith time, adjacent bubbles touch andcoalesce, growing to a size that allowsthem to rise up through the liquid, againstgravity, until reaching the surface.

(2) Microstructure refinement andmodification effect: The alternatingpressure achieved by application ofultrasonic vibrations above the cavitationthreshold generates low pressure (almostvacuum) bubbles in a liquid metal, whichstart growing, pulsing with a continuousexpansion/compression regime and finallycollapse. During expansion, bubblesabsorb energy in the melt, under coolingthe liquid at the bubble-liquid interface,resulting in nucleation on the bubblesurface. When bubbles collapse, acousticstreaming develops in the melt,distributing the nuclei into the surroundingliquid and producing a significant numberof nuclei in the molten alloy, thuspromoting heterogeneous nucleation.

Practical problemsCurrent ultrasonic applications are basedon fixed-frequency, well tuned ultrasonicsources, whereby a number of design andmatching parameters must be respected,

MMM Ultrasonic MetallurgyThe quality and competitiveness of casting strongly depends on the quality of molten alloy and thetechnology used to produce it. With regards to quality, the casting of aluminium alloys is not easy, sincealloys are prone to dendritic and heterogeneous structures, as well as the absorption of hydrogenduring melting, which requires a specific melt processing operation in order to reduce and control thelevel of porosity in a microstructure after solidification. By H. Puga*, M. Prokic**, N. van Dongen***

Fig 1. Windows compatible software developed by MPI

*CT2M – Centre for Mechanical and Materials Technologies, University of Minho, Portugal**MP Interconsulting, Switzerland ***Alupro-MPI Ultrasonics Inc., Germany



presenting practical and ultrasonicefficiency problems. These basicrequirements limit large scale and practicalapplications in laboratory scale testing.Tests have demonstrated that in order toachieve a high efficiency treatment,ultrasonic systems must be well tuned tothe load. Since most ultrasound units workinherently in non-stationary conditions,they must, in theory, continuously adaptthemselves to a load to maximiseefficiency, which is difficult to achieve withfixed-frequency units. To meet thischallenge, Multi-frequency, Multimode,Modulated (MMM) signal processingtechniques have been developed by MPInterconsulting[3].

As a result, MMM technology hasbecome the first to achieve – Wideband-frequency, uniformly spatially distributed,High-power Ultrasonic agitation – inexisting metallurgical equipment,regardless of its mass, load size, andparticular operating conditions. Moreover,the application of the new signalprocessing techniques in existing systemsdoes not involve significant designmodifications.

MMM technology applied inmetallurgyMMM technology is characterised bysynchronously exciting many vibrationmodes through coupled harmonics and

sub-harmonics in solids and in containerswith liquids. This technology produceshigh intensity multimode vibrations thatare spatially uniform and repeatable, thisway avoiding creation of stationary andstanding waves, so that the wholevibrating system is fully and uniformlyagitated, improving therefinement/modification process. Theultrasonic power supply unit is fullycontrolled by Windows compatiblesoftware developed by MPI (Fig 1).

Optimal ultrasonic processingparameters as: Frequency sweepinginterval, sweeping repetition rate, andfswm (frequency shift with modulation) forthe selected carrier, resonance frequencyand electric power are adjusted in order toproduce the highest acoustic amplitudeand the wide frequency spectrum in themelt, which is monitored with specificallyimplemented feedback loops[4]. ThusMMM technology applied to non-ferrousalloys melt treatment can produce metalspurification, microstructure refinement,structure modification and degassing,based on the specifically created acousticfield introduced in a molten metal in orderto create spatially and uniformly welldistributed and wideband multi-frequencycavitation.

During recent years, the technique formelt treatment was developed and appliedin non-ferrous alloys[5,6]. Based on the

results achieved from laboratorial research,a generalised ultrasonic treatment processwas extrapolated to be applied onindustrial scale.

By applying a different mechanicaldesign and signal processing approach inultrasonic, laboratorial scale metalprocessing equipment, it has createdrefined ultrasonic methodology, whosemain advantages are high degassing rate,uniform sonocrystallisation and micrograin refinement; consequently reducingporosity, as shown in Fig 2. On the otherhand, this technique doesn’t require metalstirring, as the alternative processes, thus itdoesn’t destroy the protective aluminiumoxide present at the surface of the melt,avoiding its introduction in liquidaluminium and keeping its protectingeffect against atmospheric contaminants.Moreover, the cavitation effect promotesthe wetting and removal of non-metallicinclusions from the melt, playing a majorcontribution to obtain high sanity castings.Additionally, the generated dross isreduced allowing negligible environmentalimpact.

Beside ultrasonic vibrations to improvecastings quality, by promoting meltdegassing and the formation of non-dendritic and globular -Al grains, it hasalso been reported that ultrasonictreatment modified the morphology ofintermetallic compounds. Recent resultsobtained in hypoeutectic Al-Si alloys usingMMM technology proved that it is possibleto convert the plates of -phase to a finepolyhedral morphology, or to change themorphology of -phase needles to refinedChinese script shaped compounds.

Fig 3(a) and 3(b) show themicrostructure of the sample withoutultrasonic treatment, and ultrasonicallytreated by MMM technology, respectively.In samples that were ultrasonically treatedby MMM technology the intermetallicparticles appear as hexagonal crystals, ofwhich the chemical composition and EDSspectrum were found to be similar to thoseof the intermetallic -phase present in thenon-US treated sample.

Results suggest that the application of

Fig 2. (a) Density of the AlSi9Cu3 alloy as a function of ultrasonic degassing time; (b) porosity in sample before US degassing; (c) porosity in sample after 3 of US degassing

Fig 3. SEM image showing the morphology of intermetallic compounds present in: (a) non-US sample treat; (b) US sampletreated

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acoustic energy changes the morphologyof the -phase from a Chinese script shapeto polyhedral crystals. Moreover, theformation of -phase is suppressed, whichcan be explained by the theory proposedby Narayanan et al.[7], i.e. if almost all ironis used in the crystallisation of -phase,when the solidification range of -phase isfinalised, there is no iron available to formthis phase, and its formation doesn’t occur.

In conclusion, the experimental resultssuggest that ultrasonic processing has thepotential for a more energy efficient scale-up for production of critical and advancedmetal compounds, leading to costreductions, energy savings, and manyother benefits.

Stepping from the laboratorialexperiment to an industrialenvironment A comprehensive experimental study onthe aluminium melt treatment throughultrasonic system based on MMMtechnology has been developed anddiscussed during the last several years. Themain objective is to provide anexperimental verification and validation ofthe theoretical mechanisms, as well as toverify the resistance and reliability of MMMtechnology components. This experimentalprocedure complements the theoreticaland laboratorial studies in the literature,and provides an appropriate knowledgefor continuous innovation in relevantindustrial activities including design,construction and applications of ultrasonicvibration equipment based on MMMtechnology.

MP Interconsulting[8] has beendeveloping ultrasound equipment for usein the metal processing industry. Thecompany is promoting an integration ofCAD and CAE systems (Fig 4) in the searchfor optimal ultrasonic processorperformances from design tomanufacturing. According to differentcriteria, laboratorial pre-established

methodologies, mathematical concepts,and a number of successfully realisedapplications, the process of creating anddelivering ultrasonic vibrations to liquidmetals is optimised. Fig 5 shows anexample of modern design methods andultrasonic equipment applied in industrialenvironment.

Fig 6 shows the variation of hydrogencontent in the melt of alloy of the series3xxx along of time in Continuous castingwith a maximum flow rate of1.1m/minute. The hydrogen content wasmeasured with the “Alu Speed Tester”equipment based on the first gas bubbleprinciple. The results show that the use ofthe innovative and sophisticated ultrasonicequipment based in MMM technology andwith ceramic sonotrode radiator(according Fig 5(a)) is possible to remove45-50% of hydrogen under the followingparameters: f=20.3±0.1kHz (stable intime), A=50% and T=700±5ºC.

ConclusionsThe ultrasonic processing technique formelt treatment was developed and appliedin different non-ferrous alloys. Based onthe results achieved for different alloys, themain conclusions that can be drawn are:(1) Ultrasonic degassing can be anefficient process to degas molten non-ferrous alloys in industrial scale.(2) When compared with the traditional,fixed-frequency ultrasonic processors,MMM ultrasonic technique seems toimprove the ultrasonic degassing processby increasing the final alloy density anddegassing rate.(3) Ultrasonic processing by MMMtechnology is an external supply of energy– presenting physical process -environmentally clean and efficient thatpromotes uniform refinement of primarygrains, modifications of intermetallicphases and eutectic Si, and decrease ofporosity in non-ferrous alloys.(4) Ultrasonic treatment clearly improvesfinal mechanical properties and fluidity oftreated alloys. �

References[1] European Commission. Integrated PollutionPrevention and Control: Best Available Techniques inthe Smitheries and Foundries Industry. (2005).[2] Eskin, G. I. Cavitation mechanism of ultrasonicmelt degassing. Ultrasonics Sonochemistry 2, S137-S141, doi:http://dx.doi.org/10.1016/1350-4177(95)00020-7 (1995).[3] Prokic, M. (European Patent Application, 2001).[4] Prokic, M. Wideband Multi-Frequency,Multimode, and Modulated (MMM) UltrasonicTechnology. 125-140, doi:10.1007/978-1-4419-7472-3_5 (2011).[5] Puga, H., Barbosa, J., Seabra, E., Ribeiro, S. &Prokic, M. The influence of processing parameters onthe ultrasonic degassing of molten AlSi9Cu3aluminium alloy. Materials Letters 63, 806-808 (2009).[6] Puga, H., Costa, S., Barbosa, J., Ribeiro, S. &Prokic, M. Influence of ultrasonic melt treatment onmicrostructure and mechanical properties of AlSi9Cu3alloy. Journal of Materials Processing Technology 211,1729-1735 (2011).[7] Narayanan, L. A., Samuel, F. H. & Gruzleski, J. E.Crystallization behavior of iron-containing intermetalliccompounds in 319 aluminum alloy. Metallurgical andMaterials Transactions A 25, 1761-1773,doi:10.1007/BF02668540 (1994).[8] http://www.ultrasonicmetallurgy.com/

Fig 4. Integration of CAD and CAE systems: (a) CAD; (b) CAE; (c) final product

Fig 6 Hydrogen content inthe melt of alloy of theseries 3xxx along of time inContinuous casting

Fig 5. Different design options applied in industrialenvironment during Continuous casting: (a) degassingsystem; (b) refinement system

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Efficiency of degassingwith US based in MMT technologyWithout US

Reduce rolling fl uid processing costs and HSE issues with Tough Ultra Filtration (TUF™) technology from CRS.

Improve the quality and volume of recovered oil with TUF, an advanced fi ltration solution that eliminates the need for costly DE and disposable fi lter media. Customizable to meet each application’s requirements, TUF is a proprietary, service-based off ering that lowers operational costs, improves product quality and helps achieve environmental improvement goals.

For detailed information on advanced fi ltration and recovery solutions from CRS, visit www.EliminateDE.com.

DE fi ltration technology has a lot of holes in it.

TM

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Dynamic Concept focuses on improvingand updating already installed productionline and facilities using the latesttechnologies. The company looks for waysto improve and customise the existingequipment rather than trying to supply off-the-shelf solutions.

A major resource at Dynamic’s plant inSaguenay is the well equipped assemblingand testing shop. Here the R&D projectscurrently being carried out use advancedtechniques such as 3D simulation andthermal analysis. The company also hasaccess to an experimental casting facilityable to cast DC slabs where improvedmould designs can be evaluated.

Casting pit technologyProminent amongst Dynamic Concept’sactivities is their programme of workfocussing on providing upgrades andsolutions for DC casting. The benefits inthis area are:� Full automation using laser technology -here the objective is an operator freeprocess bringing major benefits fromimprovement of operation safety, recoveryimprovement and slab or ingot productquality. � Automated and programmable mouldlubrication - now often manual and notprogrammable. � Table mould densification therebyincreasing the number of moulds on a pitallowing increased production capacity.Adding two moulds to a 14 strand T bartable brings a 15% increase in capacity, asat Alcoa Deschambault, Quebec. � New moulds - state-of-art technology

and improved designs.� Unitised tooling- allows preparation tobe carried out remote from the casting pitto achieve increased casting pit utilisation.It also gives precise alignment of thecasting table assembly and bottom blockeliminating operator adjustment.� Overall the above upgrades together canresult in up to +25% increasedproduction.

Examples of projects completed inDC casting at two plants in NorthAmerica:

Alcoa, DeschambaultThe plant wished to raise its productioncapacity by 15% without major investmentin a new casting line and asked DynamicConcept to evaluate the options. After anextensive analysis, covering all aspects thatmight be impacted by two possibleschemes envisaged, it was decided toproceed with a project which involvedkeeping the same mould dimensions andincreasing the number of moulds on the

casting table. One significant advantage ofthe table densification option was that notraining of employees nor operationaladjustments to the existing equipment,such as the sawing system, would beneeded.

The next stage of the project involvedon-site collection of data andmeasurements, conception & design, anddetailed engineering work. This wasfollowed by manufacturing, assemblingand dry testing.

Finally, the new densified casting tablewas supplied to the Deschambaultcasthouse and installed with anexperienced Dynamic Concept teamoverseeing its installation.

The commissioning programme wentsmoothly from the first cast; a hugecompliment to all involved in the project.The Deschambault plant now has one ofthe few casthouses in the world capable ofcasting vertically.

Alcoa plans to install a second densifiedtable at Deschambault; identical to thefirst. This will allow more flexibility to itsoperations, particularly in regards to thegoal of increasing the number of alloysproduced at the site.

Usine Laterrière, QuebecDynamic Concept carried out a majorcasting pit refurbishment project at UsineLaterrière in Canada that resulted in theproduction of their largest ever DC castslabs measuring 584mm thick, 2,518mmwidth, 807mm length. �

Contactwww.dynamic-concept.cawww.mqpltd.com

Dynamic Concept providesengineering solutionsMQP, a UK based company, has recently entered into an agreement with a Canadian company, DynamicConcept, to represent it in Europe. The two companies see this collaboration as an ideal means to bringengineering expertise to European casthouses and smelters. By Michael Bryant*

Thermal analysis during DC slab castingDesign of new densified 16 mould AlcoaDeschambault casting table

* Marketing manager, MQP Ltd, UK

Newly designed mould table at Usine Laterrière Alcoa Deschambault 16 mould casting table pre-assembled in Dynamic Concept workshop

VI International Congress and Exhibition

15-18September

2014

Congress Sections• Mineral and raw materials sources of non-ferrous and precious metals

• Current technologies of mineral raw materials extraction

• Alumina and bauxite production

• Non-ferrous and rare metals production

• Aluminum reduction technology

• Silicon production

• Precious metals production

• Carbon and carbon materials

• Casting of non-ferrous metals and alloys

• Thermal and pressure metal treatment

• Ecology, economics, finances, projects in mining and metallurgy

Exhibition Subjects• Raw and other materials

• Tools and equipment

• Automated process control systems

• Equipment maintenance and repair

• Transport and logistics

• Ecology, wastes processing and disposal, labor protection,

operational safety

• Consulting, engineering, investment projects

• Scientific investigations and innovative R&D projects

Sponsors Official

PR-partner

Organizing committee:+7(391) 269-56-47

[email protected]

KrasnoyarskRussiaNON-FERROUS

METALSMINERALS

NON-FERROUSMETALS &MINERALS

&

The Congress program includes: XX Conference “Aluminium of Siberia” X Symposium “Gold of Siberia” VIII Conference “Metallurgy of Non-Ferrous and Rare Metals” Mining and Geology Conference

Informational partners

VI Inter

national rONN

CongressOUN FERR

s and ExhiUS

Krasnoyarsk

MINERALSMETNON-FERROUS

The Congress program includes:

ONN

MMINERALS

&ALSTTANON-FERROUS

X Symposium “Gold of Siberia” XX Conference “Aluminium of Siberia”The Congress program includes:

OUN-FERRSALMETSMINERAL

&

X Symposium “Gold of Siberia” XX Conference “Aluminium of Siberia”

15-US Russia

[email protected]

+7(391) 269-56-47Organizing committee:

2014September

oductionrecious metals p• Pr

oductionr• Silicon p

eduction technology• Aluminum r

e metals pous and rar• Non-ferr

oductionr• Alumina and bauxite p

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• Mineral and raw materials sour

ess SectionsCongr

oduction

eduction technology

oductionre metals p

oduction

ent technologies of mineral raw materials extraction

ecious metalsrous and pces of non-ferr• Mineral and raw materials sour

ess Sections

Mining and Geology Conference VIII Conference “Metallurgy of Non-Fer

operational safety

• Ecology

ra• TTr

• Equipment maintenance and r

• Automated p

oo• TTo

• Raw and other materialsecious metals

Mining and Geology Conferencerous and Rare Metals” VIII Conference “Metallurgy of Non-Fer

operational safety

ocessing and disposal, labor prastes p, w• Ecology

ransport and logistics

epair• Equipment maintenance and r

stemsol syocess contrr• Automated p

ools and equipment

• Raw and other materials

Exhibition Subjects

rous and Rare Metals”

[email protected]

otection, rocessing and disposal, labor p

sSponsor

, economics, finan• Ecologyy,

e metal tressurr• Thermal and p

ous metals and alloy• Casting of non-ferr


ecious metals p

PR-partner

Official

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Informational partner

• Scientific inv

• Consulting, engineering, inv

operational safety

gyojects in mining and metallur

sInformational partner

ativestigations and innov• Scientific inv

estment p• Consulting, engineering, inv

operational safety

ojects re R&D pativ

ojectsrestment p

48 ENVIRONMENT


The aluminium industry has long been onthe leading edge of sustainability formanufacturing in North America.Lightweight, strong and infinitelyrecyclable, aluminium is a material ideallysuited to drive energy efficiency inapplications ranging from fuel-efficienttransportation to green building tosustainable beverage packaging.

In the early 1990s, the industry entereda voluntary partnership with theEnvironmental Protection Agency (EPA) tolimit its greenhouse gas emissions. Thiseffort was recognised by the Agency withthe 2001 Climate Change ProtectionAward.

Aluminium also has unique benefitsonce it is put into use. Infinitely recyclable,the metal has the smallest life cycle carbonfootprint of all materials in thetransportation market. Aluminiumcontributes unique energy benefits togreen buildings and around 95% ofaluminium used in buildings today isrecycled. Aluminium beverage containersare the most recycled – and recyclable – ofall containers in the marketplace.

As a result of these benefits, severalmajor aluminium companies arerecognised on the Dow Jones SustainabilityIndex. The list goes on.

One key element of the industry’ssustainability approach is ongoing researchto track and monitor environmentalstewardship. A Life Cycle Assessment (LCA)study released in January 2014 by theAluminum Association is the latest in abody of research bolstering the industry’senvironmental claims.

Energy demand and GHG emissionsin declineThe Aluminum Association began usingthe LCA approach to track theenvironmental impact of the industrynearly 20 years ago, when the practice wasin its infancy. A LCA is a technique thattracks the environmental impact of aproduct in all stages of its life, from rawmaterial extraction to production and useto disposal or recycling.

“Back when we began conducting LCAresearch, very few companies – let alonetrade associations – were doing this typeof work,” said Charles Johnson, vicepresident for policy at the AluminumAssociation. “Even today, relatively fewindustries provide the type of detailed,transparent information that we do aboutthe impact of our product.”

The Aluminum Association has releasedfour LCA reports to date – in 1993, 1998,2010 and most recently at the beginningof this year.

The latest report shows severalsignificant improvements for the industry.According to the latest data, the energyneeded to produce a single metric ton ofprimary aluminium by plants in the USAand Canada has declined 11% since 2005and 26% since 1995. The industry’scarbon footprint has fallen even moredramatically, declining 19% since 2005and 37% since 1995.

A variety of factors appear to be drivingthis change. First, in 1992, the aluminiumindustry entered into a voluntarypartnership with the EPA to reduceemissions of perfluorocarbons (PFC), agreenhouse gas.

These efforts were extremely successfuland by the 2010 production year, PFCemissions were down fully 85% from the1990 baseline.

Secondly, the industry itself is changing.Many smelters relying on older productiontechnologies including the Söderbergmethod, have come offline in recent years,replaced with cleaner-running plants.Smelters also rely increasingly oncomputerised controls to limit the energywasted in the production process.

And finally, more and more primarysmelting plants in the USA and Canadarely on renewable hydroelectric power torun their operations.

The share of hydropower consumptionfor aluminium production has risen from63% in 1991 to 75% today. At the sametime, less than a quarter of all productioncapacity today relies on coal-fired powerversus 35% in 1991.

LCA study bolsters aluminium’ssustainability advantage

49www.aluminiumtoday.com ENVIRONMENT


A Vital Research ToolThe full LCA report, which is available atwww.aluminum.org/LCAReport, containsmore than 120-pages of detailedbackground and data on every aspect ofprimary and secondary aluminiumproduction as well as semi-fabrication. Thereport tracks aluminium from “cradle togate” meaning that the use phase ofaluminium products are outside the studyboundaries. The industry is working onproduct-specific LCA reports tocomplement this work.

The study reviewed the 2010 productionyear and incorporates information from 25companies, representing 95% of primarymetal production and the majority of theindustry in the USA and Canada.

“Ultimately, this study was developed forthe research community so it wasimportant that we take a completetransparency approach in developing thedata,” said Marshall Wang, AluminumAssociation sustainability specialist andprimary author of the report. “Aluminiumcompetes very favourably againstcompetitor materials which means we arevery comfortable being open about theimpact of our product.”

A third-party expert on LCA reviewed the

report to ensure conformance withInternational Organisation forStandardisation (ISO) standards. The reportis now being widely distributed to theresearch community for use in future lifecycle comparison studies trackingaluminium versus competing materials.

More progress to be madeWhile there is still room for the industry toimprove its environmental impact throughadvances on the production side, mostfuture progress will rely on substitutingaluminium for heavier, less energy efficientmaterials.

“It’s encouraging to see how aluminiumproducers continue to innovate to makealuminium even more sustainable,” saidHeidi Brock, president & CEO of theAluminum Association.

“We can also achieve significantenvironmental gains by substitutingaluminium in more products and byincreasing end-of-life recycling.”

Aluminium can increase the fuelefficiency of vehicles throughlightweighting, improve energy efficiencyin buildings and limit carbon footprint ofconsumer goods like beverage containers.A 2009 study showed that lightweighting

passenger vehicles with aluminium inNorth America saved the equivalent of 108million barrels of crude oil and offset fully92% of the industry’s overall carbonfootprint. Aluminium roofs, meanwhile,reflect up to 95% of sunlight, dramaticallylowering air conditioning costs.

Another area for industry improvementis increased recycling. Aluminium is amaterial ideally suited for this purposebecause it can be recycled over and overagain without any loss in its usability. Andmaking recycled aluminium requires just8% of the energy compared to newaluminium. This means that a 10%increase in end-of-life recycling ratesdecreases primary energy demand andcarbon footprint by 15%.

As energy becomes an increasinglyprecious commodity in the coming years,aluminium is uniquely well suited torespond to this global challenge.Increasingly, the world is looking forinnovative solutions to operate moreeffectively and efficiently. And aluminiumcan be a major part of the answer. �

Contactwww.aluminum.org

Partners

4

Organised by

ALUMINIUM 2014

10th World Trade Fair & Conference

www.aluminium-messe.com

7–9 Oct 2014 | Messe Düsseldorf



Novelis’ recycling plant, located inWarrington, UK, was opened in 1991,although aluminium has been processedat the site since the Second World War.

The plant produces ingots for thebeverage can manufacturing industry andhas the capacity to recycle around130,000 tonnes of used beverage cans(UBCs) per annum – more than everyaluminium drink can sold in the UK.

The UK can market is approximately110,000 tonnes per year, which isequivalent to more than seven billion cans.

“We produce large ingots that go intoNovelis’ rolling stream for the productionof can and automotive sheet,” says SteveHedar, plant manager. “Aluminium holds avery positive message when it comes torecycling, as it is well-known for not losingany of its qualities even when recycledinfinite times.”

Cans into cansThe majority of the cans to be recycledarrive at the Latchford plant frommanagement waste companies.

“We have contracts for supply and wealso buy from smaller traders,” says KateRavenscroft, communications manager.“Quite a lot of the material used to comefrom community groups. It was alwayswell sorted and clean, but a lot of thesehave now lost funding.”

As the sources for material havechanged over the years, so has the volumebeing produced.

“With a production rate of 200,000tonnes per year, a lot of aluminium needsto be brought on site, sorted and thenprocessed, so we try to deal with largerorganisations who can guarantee thevolumes required,” says Kate.

The can sheet produced on site issuitable for the ‘evercan’ product, which is

Keeping aluminium in the closed-loopIn the UK, Novelis Recycling is atthe forefront of driving thedevelopment of theinfrastructure for aluminium canrecycling. Nadine Firth* visitedthe Latchford recycling plant tosee first-hand how the companyis developing closed-looprecycling to help reach its 2020sustainability goals.

the world’s first certified high recycledcontent material for beverage cans.

Made of a minimum 90% recycledaluminium, evercan sheet is certified byScientific Certification Services (SCS), anindependent leader in environmentalauditing.

Proving that used beverage cans are avaluable resource, evercan sheet aims toclose the loop between consumerrecycling and new cans.

SortingIncreasing the levels of recycled contenthas lead to significant investment insorting equipment at the plant.

“The enemy of recycling is mixing,” saysSteve. “Co-mingled material will alwaysprove harder to sort and so we haveinvested in new sorting equipment at theplant to tackle this and to reach the levelsof recycled content required for evercansheet.”

Automotive investmentTowards the end of 2013, the plantreceived a €13.6 million (£6 million)investment to increase its capacity by overa third and become Europe’s largestclosed-loop recycling operation forautomotive aluminium rolled products.

“With the commissioning in Latchford,we are expanding our recycling capabilitiesand developing efficient manufacturingsystems along our automotive supplychain,” Erwin Mayr, senior vice presidentand president, Novelis Europe, said in astatement. “Responding to the realities ofour increasingly resource constrainedworld and demands for a moresustainable economy, Novelis istransforming its business model to belargely based on closed-loop recycling.”

Much of the additional capacity will be

directed to support the industry’s growingdemand for automotive aluminium sheet,particularly from Jaguar Land Rover (JLR),one of Novelis’ long-standing customers.The investment in new equipment forrecycling automotive aluminium scrapincludes a dedicated furnace, upgradedcasting system, magnetic separation andhandling equipment, as well asenvironmental controls.

During the recycling process, the scrapis re-melted and cast into 10-12 tonneingots, each saving approximately 100tonnes of greenhouse gas emissions whencompared to ingots produced fromprimary aluminium. The ingots are thensubsequently rolled back into automotivesheet at Novelis’ specialised facilities inEurope.

This emerging closed-loop modelreduces the environmental footprint ofNovelis’ operations and that of itscustomers, such as JLR. This expansion willresult in nearly 530,000 tonnes ofgreenhouse gas savings over the totalaluminium value chain compared to usingprimary aluminium. Furthermore, theclosed-loop model strengthenscooperative, long-term relationships withmajor global customers, driving thedevelopment of innovative, sustainableproducts and processes.

This project is the latest in a series ofrecycling expansion projects launched byNovelis over the past two years totallingapproximately €680 million. These projectsare designed to increase Novelis’ recyclingcapacity to 2.1 million tonnes by 2015and help the company achieve itsaggressive goal of increasing the recycledcontent of its products to 80% by 2020.

Contactwww.novelisrecycling.co.uk

�

*Editor, Aluminium International Today

52 ENVIRONMENT www.aluminiumtoday.com


As attention is drawn towards the sectorsof renewable energies, buildings andtransportation, to fight climate change,energy-intensive industries shall not be leftaside as they are also part of the solution.

Aluminium is a striking example, as anincrease in demand for aluminium isexpected in the future[1] in order to lightenvehicles and aircrafts and reduce their fuelconsumption. However, the environmentalfootprint of aluminium is higher than thatof other structural materials[2].Consequently, a transfer of impacts fromthe transport sector to the industry mayoccur if no effort is made at the same timeto reduce the environmental footprint ofaluminium production.

Today, aluminium makes up 4% ofgreenhouse gases emissions fromindustry[3]. Greenhouse gases (GHG)emissions related to aluminium productionare mainly due to intrinsic CO2 emissionsgenerated by alumina reduction, electricityfor electrolysis (indirect emissions), and useof fossil fuels for mining and electrodesfabrication. Other environmental impactsinclude gases emitted by electrolysis pots(perfluorocarbon, hydrogen fluoride (HF),SO2), PAH emissions from green anodeplants, NOX and particles from anode-baking furnaces and casthouse furnaces.

Significant progress has been achievedby the industry to reduce perfluorocarbon

emissions from anode effects, to lowerelectricity required in electrolysis pots (nowdown to 13.5 kWh/t alu instead of 16) andto increase recycling rates of aluminiumand dross. As a result, the potential forsignificant reduction in smelter direct andindirect GHG emissions has already beenwidely and successfully exploited. To gofurther in reducing their environmentalfootprint and their electricity bill,aluminium producers need to investigatenew areas of improvement such as:

• Energy efficiency in other parts of theprocess than electrolysis pots (anodesfabrication, gas treatment centres,casthouse furnaces),• Recovery and use of energy from potgases cooling,• Reduction of HF and SO2 emissionsfrom pot gases,• Modulation of pots amperage to beflexible towards electricity price variations,• Synergies with nearby industries tovalorise waste streams.

Several technologies from Fives Solios(green anode plants, gas treatmentcentres, melting & holding furnaces) arekey to address these challenges. For thisreason, these technologies have beenselected to be part of a corporate eco-design programme.

A company-wide eco-designprogramme A leader in many energy-intensiveindustries such as aluminium, steel,cement or glass, Fives Group strives tominimise environmental impacts of itstechnologies. Fives decided that itsinnovation efforts would focus in priorityon environmental performance, not only inits activities that are directly related toenvironment protection (e.g. GasTreatment Centres for the aluminiumindustry) but also for any kind of industrialequipment supplied by the Group.

This strategy has been implementedwithin the product development processwith a programme called EngineeredSustainability. This programme is both aninternal quality process and a brand:• A process for systematically reviewingimpacts and continuously improving Fivestechnologies, and for providing customerswith quantified data and resources toachieve the best-possible performance inoperation.• A brand for Fives best-in-class productsin terms of environmental performance.

The Engineered Sustainability(R)

programme follows ISO 14062recommendations and has been reviewedby Ernst&Young, an independent auditfirm.

Fives Eco-Design programmeFives Solios decided to embed eco-design in its innovation process and presents a new process filtermodule, Ozeos, which features high environmental performance. By Pauline Plisson*, Bassam Hureiki**, and Chin Lim***

*Innovation and Sustainability Program Manager, Fives Group **Key Account Manager, Fives Solios ***Innovation Manager, Fives Solios

100% 100%

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60% 60%

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0% 0%Climate change

Climate change

Human health

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Impact onecosystems

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Scarceresources

Scarceresources

Water stressindicator

Water stressindicator

Compressed Air-Air

Ozeos

TGT-RI

Electricity - Fluidization air

Electricity - Pressure loss

Emissions -Emissions to air

Maintenance -Filter bags

Maintenance -Filter cage

Fig 1 Life Cycle Assessment of TGT-RI (exploitation phase only) performed with QuantisSUITE 2.0

Fig 2 Life Cycle Assessment of TGT-RI versus Ozeos, performed with Quantis SUITE 2.0


remains a key challenge for aluminiumindustry and must be a field of continuousimprovement for GTC suppliers.

Filter bags, which are consumables asthey must be replaced every five years,appear as a minor priority but are stillworth efforts to reduce the GTC’s overallenvironmental impact.

As explained earlier, the EngineeredSustainability programme tackles moretopics than those covered by the LCA,such as maintenance requirements,footprint, weight, noise, etc. An analysisof Fives’s GTCs performance and ofaluminium producers’ sensitivity to thoseaspects has therefore been performed.

By combining the results of the LCA andof the other analyses performed, severalareas have been listed by Fives Solios toimprove the environmental footprint of aGTC, including:• HF emissions• Pressure drop in filter modules,including reactor (related to electricityconsumption)• Compressed air consumption• Maintenance requirements• Footprint and weight• Bags lifetime.

Ozeos, an eco-designed processfilter module for GTCs

A new generation of GTCprocess filter modules hasbeen developed by FivesSolios over the last fewyears. It is called Ozeos andhas been tested since 2005in Saint-Jean-de-

Maurienne, France. It hasbeen implemented in 2013

for the first time at industrialscale in Jonquiere (Canada), in a

plant operated by Rio Tinto Alcan on newAP60 pots.

Ozeos main innovations include thefollowing improvements on the filter:• Lower ground footprint• Easier maintenance• Lower electricity consumption • Optimised alumina injection andcirculationA complete sustainability assessment,

Fig 3. HF efficiency function ofgas temperature & scrubbingtechnology

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1.6

1.4

1.2

1106 108 110 112 114 116

Gas temperature inside GTC filters

118 120 122 124 126 128 130

HF

incr

ease

rat

io

Competition’s curve, source TMS 2012Solios’ curve

• Human health• Ecosystems• Scarce resources, when the productimplies depletion of non-renewableresources• Water stress, when the product impliesuse of water in water-stressed areas.

The assessment was conducted for onetypical GTC of 16 filter modules treating 2000 000 Nm3/h of pot gases,corresponding to an annual aluminiumproduction of 185,000 tons, equippedwith TGT-RI filter modules designed byFives Solios. All components of filtermodules have been assumed to bemanufactured in Europe and shipped tothe Gulf area except steel, assumed to beproduced locally. A GTC lifetime of 30years was considered, as well as a bagslifetime of five years.

The results led to a clear firstconclusion: only the exploitation phasehas a significant environmental impact.

A deeper look into this phase highlightsthat environmental impacts are primarilyrelated to electricity and compressed airconsumption (Fig 1). As the mainfunction of a GTC is to cut HF emissionsdown to the lowest possible, the overallimpact of residual pollutants remaining ingases after filtration is minimal. It isdisplayed in the "Impact onEcosystems" indicator (Fig 1).However, due to increasinglystringent regulatorystandards, this matter

The programme involves technical andsales teams from the early stages ofdesign and relies on an eco-design toolkit.A range of aspects are assessed, such asenvironmental (energy consumption andemissions but also noise, consumables,floor space, etc.), economic (lifecycle cost,production flexibility, etc.) and humanimpacts (e.g. training operators in themost effective and safe use oftechnology). Opportunities to reduce themain impacts are systematically listed,studied and implemented when they aresuccessful; and their benefits are proven.

As of January 2014, four eco-designprojects have been completed, 10 projectsare on-going, and about 100 people fromFives have been trained to eco-design.

Gas Treatment Centres’ mainsources of impactsThe Gas Treatment Centre (GTC) is criticalon various aspects for the aluminiumproduction process. First of all, it suppliesfluorinated alumina, which is capital tooptimise aluminium production atelectrolysis phase. Also, it maintains a safeenvironment for operators and in thevicinity of aluminium plants as iteliminates pollutants (hydrogen fluoride(HF), dust) contained in gases emitted byelectrolysis pots.

A Life Cycle Assessment (LCA) of a GTChas been performed by Fives Solios. TheLCA method allows estimating theenvironmental impacts generated by atechnology over its life cycle(manufacturing, transport, exploitation,end of life). It takes into account bothdirect impacts (e.g. electricityconsumption for fans, compressed airsupply, etc.) and indirect impacts(e.g. CO2 emitted for manufacturing thefilter bags). Results are aggregated underthe form of five main indicators:• Climate change (includes mainlygreenhouse gases emissions)

Enhanced lifetime-20% HF

emissions

Optimum balance between compactdesign and performance

Easy access and reduced maintenance

-5% electricalconsumption

in GTC

Summary of Ozeosbenefits compared to theBenchmark

May/June 2014

ENVIRONMENT www.aluminiumtoday.com


54

covering the topics listed above, has beenperformed in order to:• Check that design improvements didnot generate a transfer of impacts, i.e. thatOzeos scores better than other benchmarkfilter modules on all sustainabilityindicators. This was achieved through acomparative LCA and additionalcalculations.• Quantify Ozeos’s environmentalperformance, by analysing site data fromSaint-Jean-de-Maurienne pilot andJonquiere plant.

After performing an entire LCA on theOzeos, the comparison of Ozeos and TGT-RI assessments led to the conclusion thatno transfer of impact occurred whiledesigning Ozeos, as shown on Fig 2.

The lower overall environmental impactof Ozeos can be explained by multipledesign improvements.

First of all, the amount of materials(plastic, polyester, steel) has been reduced,thus leading to a lower filter moduleweight and a reduction of indirect impacts(transportation and erection costs, etc.).The other resulting benefit is an optimisedground footprint, as the Ozeos is 55%more compact than Fives Solios’s formerbenchmark for an equivalent filteringsurface. Fives Solios estimates that it has

now reached an optimum balancebetween compact design andperformance.

Also, electricity consumption has beendecreased thanks to low speed gasgradient in the new design of the reactor-filter couple. The reduced pressure dropgenerates 5% savings on GTC’s electricalconsumption compared to the benchmark,corresponding to an annual $300,000electricity savings for a 740,000 T/yearaluminium smelter. In terms of environmental performance,analysis of various site data led to theconclusion that Ozeos reduces HFemissions by at least 20% compared to theformers state-of-the-art technologies, andthat HF emission performance is lesssensitive to gas temperature (Fig 3). Thisperformance results principally of animproved mixing of alumina and gas, andan optimum gas velocity gradient in thefilter module.

Thanks to all these benefits, Ozeos hasobtained the Fives EngineeredSustainability brand, thus classifying it as abest-in-class product in terms ofenvironmental performance.

In addition to the Ozeos, anotherproduct developed by Fives Solios has justbeen distinguished by the Engineered

Sustainability brand: Genios, anelectromagnetic stirring and castingsolution for the casthouse. �

References [1] International Energy Agency, Energytechnology transitions for Industry, 2009[2] Cooperation and competition amongstructural materials, J-P Birat et al, Revue deMetallurgie, 2013[3] World Resources Institute, 2005“Managing Greenhouse Gas Emissions at SoliosEnvironnement”, El Hani BOUHABILAAluminium International Today – May, 2011Emissions processing at Qatalum smelter byBassam Hureiki, Alu Solutions conference(Montreal, 2013)Eco Design implementation within Fives Groupand application to a Gas Treatment Center byPauline Plisson, Alu Solutions conference(Montreal, 2013)Centralised gas treatment centres by Antoine deGromard and Kevin Tarion – Aluminium TodayNovember 2012ISO TR 14062: Environmental management -Integrating environmental aspects into productdesign and development

Contactwww.engineered-sustainability.com www.fivesgroup.com


These challenges are faced every day at theMGG Netherlands B.V. foundry (hereafterMGG) in Tegelen, Netherlands. With anannual production of more than 12,000metric tons of cast aluminium, thecompany operates one of the largestaluminium sandcasting foundries inWestern Europe (Fig 1).

More than 400 employees, in an area of29,000m2, produce series production castparts for customers worldwide. Thecommercial vehicle, passenger car andboiler industries in particular rely on castparts produced in the Netherlands.

Foundry chemicals such as coatings andbinders for the casting process may seeminsignificant at first glance, but far from it.They play a crucial role in the productionprocess. This is why the Dutch core-moulding plant (Fig 2), which produces15,000 – 20,000 shots per week and uses400 metric tons of sand, has been working

with ASK Chemicals, a foundry supplier, foryears and uses its cold box binders.

Binder technologyIn 2011, MGG began testing the ECOCUREsolvent less binder technology (SLtechnology). Always pursuing the aim ofreducing BTX and odour emissions,improving the physical and thermalproperties of the cores and, ultimately,reducing the use of binders and amines,with this new technology (Fig 3). After anapproximately one-year testing phase,series production finally started with thenew generation of ECOCURE solvent lessbinder technology from ASK Chemicals.

CooperationA conventional cold box system can bedescribed as a three-part system:Component 1 is comprised of around 55%phenolic resin and 45% solvents.

Component 2 is mainly comprised ofpolyisocyanate derivatives and 15% to30% solvents. Finally, the tertiary aminecatalyst, which initiates the reaction, formscomponent 3. Both component 1 andcomponent 2 of the binding agent cancontain additives that are used to optimisespecial features or casting properties.

The polyurethane reaction consists ofphenolic hydroxyl groups in component 1,which react with the NCO groups(isocyanate groups) in component 2. In thesolvent less system, component 2 has beendesigned to be just as effective as a normal2-component system, but without usingsolvents. The solvent-free formulation forcomponent 2 contains a specialpolyisocyanate component. Additives thatinteract exactly with the adaptedcomponent 1 were added. With thiscombination, the total amount of bindingagents can be reduced by 20%.

Increasing requirements are driven by the ever more stringent standards for reducing emissions andoptimising quality management (ISO-TS 16949). This also affects the foundries and their suppliers.Manufacturers are expecting suppliers to provide evidence of sustainable production, due to growingpressure to produce in an efficient way. By Andrea Ferkinghoff* and Verena Skelnik**

*ProTEC Marketing**ASK Chemicals

Fig 1. The site of MGG Netherlands B.V. is surrounded by housing areas. The company therefore places great importance on keeping production as emission-free and smoke-free aspossible. Fig 2. Inside MGG’s core shop in Tegelen. Fig 3. As part of the leak test, the cast parts are tested for possible gas defects and porosities caused by shrinkage. In the area ofboiler production in particular, the rejection rate due to gas defects was reduced by more than 5% with ECOCURE SL. Fig 4. ECOCURE SL meets the highest requirements to deliversuperior quality of appearance and dimensional accuracy. Fig 5. John Huskes, Senior Production Engineer at MGG, is delighted about the excellent quality of the produced cores.

Sustainability in aluminium foundries

Fig 1

Fig 3 Fig 4 Fig 5

Fig 2


The SL technology contains VOC-freesolvents. In the formulations, the knownplant esters are replaced by these solventsto offer users the option of reducing a partof the emissions.

The physical properties of the cores thatwere produced using the new technologywere able to convince MGG. John Huskes,Senior Production Engineer at MGG, wasimpressed by the dimensional accuracyand thermal load capacity of the cores thatwere shot in Tegelen (Figs 4 and 5). Thegood core removal capability is a result ofusing less organic material whilemaintaining the same amount of oxygenduring casting. This means a reduced buildup of deposits and therefore less need fortool cleaning. By using the new generationof binders, MGG achieved a reduction of

emissions during the casting, cooling andshake-out processes, while maintainingdimensional accuracy at the same time.

As revealed by the example formulation(Fig 6), the dosing ratio is more favourablewith the new technology. In addition,MGG discovered that the sand usedreduces the absorption of moisture by60%. The rejection rate of the producedsand cores us currently at 2%. Especially inboiler production, where foundries rely onparticularly high-quality cores, the rejectionrate caused by gas defects was reduced bymore than 5%.

The environmentEnvironmental friendliness andsustainability play an important part todaywhen it comes to selecting suppliers and

foundry aids. For this reason, MGGcommissioned the Institut fürGießereitechnik (IFG) in Düsseldorf toexamine the BTX emissions and odourproduced by the ECOCURE SL system andby its rival products used to date. Here,too, the new development from ASKChemicals displayed its strengths.

While the odour generated was 20%lower (Fig 7), the BTX emissions werereduced by 60% (as compared to the othertwo cold box binders) with the ECOCURESL technology. In addition, visible smokedevelopment is a thing of the past in thisfoundry. For the foundry and not least forits employees and the people living nearbyin Tegelen, results like these are a signalthat the company is doing its best tosupport environmentally friendlytechnologies.

The best practice example highlights theimportance of the contribution made bysuppliers of foundry consumables to thefoundries’ added value. The use ofefficient, low-emission binder systemsshows that the basis for qualityimprovements and emissions reductionscan be created at the componentproduction stage by carefully selecting thecomponents and consumables for therelevant casting process. �

Fig 6 Fig 7

ENVIRONMENT56

Fig 6. The quantity of part 2 that needs to be added can be reduced by more than 20 % with the new ECOCURE SL system.Dosing quantities of the rival product: 0.52 % of part 1 and 0.52 % of part 2; dosing quantities of the ECOCURE SL system:0.53 % of part 1 and 0.40 % of part 2. Fig 7. Generation of visible smoke is a thing of the past in the Dutch foundry.

ASMP GmbH - Sales Manager

ASMP GmbH - Aluminium Silicon Mill Products - Baarerstrasse 94 - CH-6300 Zug - Switzerland

We are the exclusive marketing company for Aluminium semi-finished products from a worldwide acting Russian producer. Our sales area covers Europeas well as Asia and North- and South America. We sell our rolled products, extrusions and forgings in all commercial and special alloys to metal distributorsas well as to end users in the aeronautic and transportation industry.

To cover our ambitious goals for further growth we are looking for a

SALES MANAGERThe ideal candidate would have at least 10 years professional experience in a similar position in our industry. You are in daily close contact with internationalcustomers worldwide, the production plant in Russia, our sales team and other inside departments. A highly interesting task with further potential fordevelopment is waiting for you. If qualified, you will become responsible for your own customers or for certain countries worldwide.

If you are a team-oriented personality bringing along experience in Aluminium downstream industry and international customer service, knowledge ofletters of credit, logistics, EDP systems such as SAP as well as a flair for marketing and interest in technical product applications, then please send us yourdetailed CV. Our office language is English and German. Knowledge in other foreign languages like French, Spanish, or especially Russian would be ofadvantage. Readiness for worldwide travelling is required.

Our office is located in the center of Zug. We offer attractive compensation and exemplary social security.

Please send your application to [email protected]

RECRUITMENT: SALES MANAGER

Predictions for what the future may holdfor the industry are difficult to make; theenvironmental issues have mushroomedfrom a few to many over the past decade.These issues now include global warming,climate change, regulations, raw materialsupply, waste, pollution and naturaldisasters among others.

No other topic has divided people acrossthe globe in the past decade then globalwarming and climate change. The UnitedStates’ Environmental Protection Agency(EPA) defines global warming as: “Anincrease in temperature near the surface ofthe Earth...most often used to refer torecent and ongoing warming caused bypeople’s activities. Global warming leads toa bigger set of changes referred to asglobal climate change.” People can arguewhether or not man’s activities are havingan effect on the earth’s climate, but noone can argue that the actions taken bysome governments to address globalwarming and climate change are thebiggest threats to the industry as a whole.

The European Aluminium Associationstates: “The aluminium industry complieswith ever more demanding environmentallegislation covering emissions to air,discharges to water, handling and storageof waste and of hazardous substance.”Environmental regulations have farreaching effects to the industry. Electricityin many ways is the most important costfor primary aluminium with the AluminiumAssociation claiming: “Energy representsabout one-third of the total productioncost of primary aluminium.” Over 41% ofall electricity produced globally is by coal-fired power plants.

The countries listed in Table 1 are facedwith aging coal-fired electricity generatingplants. These are more susceptible toclosure when stricter environmentalregulations are enacted. In the United

States, over 280 coal-fired power plantsare slated to be shutdown as a result ofstricter Environmental Protection Agencyregulations. Already high energy pricescoupled with London Metal Exchangeprices, which have languished close to orbelow the cost of production for manymakers, has forced some aluminiumsmelters to shut their doors.

Ormet, an aluminium smelter located inHanibal, Ohio, USA saw its base rate toprocure power increase more than 53%from $39.66 per MWh in 2009 to$60.83/MWh in September 2013. Ormet’srequested relief to the Public UtilitiesCommission of Ohio from the“uncontrollable” power costs was denied.It said in a statement on October 4, 2013:“Due to the decision [lack of relief], Ormetcannot emerge from bankruptcy and mustimmediately shut down operations.” Thistrend, in the future, with the ever-increasing cost for electricity will result inmore primary and secondary aluminiumplants closing.

Raw materialsOver the past decade, a proliferation ofnew smelters has opened up in regionswith immature environment regulationsand subsidised electricity. As somecompanies have followed the lure of‘cheap electricity’ and ‘friendlygovernments,’ the easy access to rawmaterials (e.g., bauxite) proved to be amirage for a few companies.

Vedanta Resources’ aluminium smelterproject in India’s eastern state of Orissa

became engulfed in the perfect storm ofsocial media and environmental activistswhen developing new bauxite mines.Vedanta Aluminium spent over a decade,and in some estimates, more than $6.7billion building the complex, that includeda 1 million ton alumina refinery andaluminium smelter, prior to finalisingagreements to mine local high-qualitybauxite. The locally sourced bauxite is inthe Niyamgiri Hills, which is home to theDongria Kondh tribe. The tribe considersthe Niyamgiri Hills sacred.

In 2013, the plan to supply cheap rawmaterials to its nearby aluminiumoperations was complicated when theDongria tribe councils voted against itslatest proposal. The Dongria tribe’sresistance to the generous Vendetta offerswere buoyed by social media and thecause became so celebrated that it wasused as inspiration for characters in theblockbuster movie Avatar. When localopposition grows to become aninternational movement, not only does thealuminium company lose, so does theindustry.

The industry has done an admirable jobconstructing and maintaining red mud(produced during the Bayer Process)reservoirs. The public perception ofreservoirs changed for the worse onOctober 4, 2010 with the breach ofTimföldgyár alumina plant’s red mudreservoir in western Hungary. Over onemillion cubic meters of liquid wasteescaped affecting over 40 squarekilometres of land. Nine townspeople diedand over 120 were injured when the 1-2metre wave of red mud swept throughnearby towns and cities. Since thisincident, red mud reservoirs around theglobe have been prevented fromexpanding because of opposition fromlocal environmentalists. The spotlight will

57HEALTH & SAFETY


Numerous challenges involving environmental, health and safety issues lie ahead for the aluminiumindustry. Alex Lowery* explains.

*Wise Chem LLC, USA.

South Africa 93% USA 45%

PR China 79% Australia 78%

India 67% Russia 20%

Table 1. Coal in Electricity Generation

Health and safetyin the aluminium industry

58 HEALTH & SAFETY www.aluminiumtoday.com


remain focused on how the industrydisposes of red mud in the coming years.

There are numerous companies who aredeveloping technologies to “treat redmud”. The hope is these technologies willbe commercially viable soon and eventuallyreduce the large quantities of red muddisposed annually.

Natural disastersAluminium companies in the past yearfaced natural disasters including, wildfires,typhoons, earthquakes, floods, tornadoesetc. On November 17, 2013, a series ofsevere storms formed a north-south bandmeasuring over 900 kilometres in lengththat travelled from the Midwest to EastCoast of the United States. The stormsspawned numerous tornadoes withvarying degrees of severity affectingnumerous aluminium plants with poweroutages. One tornado formed south of thenewly constructed Nanshan AmericaAluminium plant in Lafayette, Indiana,

USA. The tornado had wind speeds up to254-333 kilometres per hour. Thealuminium workers heard the tornadowarning sirens go off, signalling a pendingtornado and followed their emergencytraining. Amazingly, the NanshanAmerican Aluminium plant was spared anysignificant damage. Neighbouringbusinesses received a direct hit from thetornado. In the future, emergencymanagement plans must take into accountall types of manmade and naturaldisasters.

Safety programmesThe spotlight has not only highlighted theindustry’s environmental issues it has alsoshone brightly upon its safety incidents. In

the past, a safety incident at an aluminiumplant might only be known locally. Now,the world can know about the smallestincident almost immediately after it occurs.

Conversely, the news media can fail toreport positive stories involving theindustry. Numerous aluminium companieslike Novelis, Alcoa, Emal, Hydro, Alba, andothers have excellent safety records. Thesecompanies’ safety programmes are used inother industries as benchmarks. It is agreat compliment when an aluminiumcompany’s safety record is used as abenchmark for companies outside theindustry. Novelis’ safety programme,known as the Novelis Safety System (NSS),creates a comprehensive system foridentifying and mitigating risk, ensuringNovelis employees work safely andmonitoring performance.

Aluminium Bahrain B.S.C. (Alba) heldtheir annual Safety Week using the theme“Together, We Build a Safe Culture”. Thecompany understands promoting andsupporting a safe work environmentaffects every aspect of their operation in apositive manner. In the future, thesecompanies will continue to lead ourindustry in creating a safe workenvironment.

HazardsThe hazards faced in the past are still inlarge part present today. Molten metalwater explosions have historically had thegreatest impact. Of all the hazards theindustry deals with on a daily basis(moveable equipment, dust/fineexplosions, confined space, lock out tagout, etc.), molten metal water explosionshave caused more human causalities andfinancial loss than any other. History islittered with companies forced to shuttheir doors after a molten metal explosion.Even without the loss of human life, theloss of production due to damagedequipment is a burden many companiescannot overcome financially.

Compared to the age of the industry,combustible dust has only been identifiedas a hazard for a short period of time,basically the past 25 years. Aluminiumfines were considered a nuisancebyproduct before being designated ahazard and were allowed to accumulatethroughout aluminium plants. Finesaccumulate on any horizontal surface inthe plant. Dust would often build up somuch on rafters and roof joists that itwould fall and look like snow falling. Floorswere only swept when aluminium fines

became a slip hazard. Aluminium fineswere then either deposited into a furnaceor a dumpster. Its nuisance byproduct labelquickly disappeared when aluminium dustexplosions occurred. Dust accumulation inolder plants is a difficult task that many inthe industry struggle with on a daily basis.Newer plants have been designed with thelatest technology allowing for thecontainment of aluminium fines at thegenerating source. In the future, astechnology evolves, this hazard will bereduced further.

Technology has also transformed thehazard of mobile equipment helpingmitigate injuries and fatalities. This hazardis unique when compared to othersbecause mobile equipment or industrialtrucks can be located in one spot and thenext minute in another spot. Not only isthere a hazard associated with theequipment operator, the mobility itself is adanger to nearby workers as well. TheAluminium Plant Safety Blog posted fivefatalities involving moveable equipment in2013. The industry will have to take aproactive approach to minimise or eveneliminate the interaction between mobileequipment and pedestrians in the future.

Changing timesWorker attrition through retirement andlayoffs is also a potential hazard. A highpercentage of middle to uppermanagement are reaching retirement agein the next five years around the world. Theworkforce will soon lose many of its mostexperienced workers. One study found that20% of the workforce will be 55 or olderby 2015. How the aluminium industrydeals with this will have lasting effects onsafety. An apprentice programme allows acompany to have a pool of experiencedemployees of different ages so that theywill be better able to meet future needs.Companies who participate inapprenticeship programmes benefit byhaving employees who are not only trainedto industry standards but also understandthe particular company's unique workplaceconditions. A recent survey of apprenticesfound that participants developed a loyaltyto the company that hired them leading toa more stable workforce.

The industry should be commended onthe diligent work it’s done to mitigateenvironmental issues and safety hazards. Inthe past aluminium companies workedindependently when addressing industryissues. Now companies realise thatworking together benefits all parties. �

Molten metal waterexplosions have causedcausalities

Ormet, Ohio, USA.

The date and venue for the triennialAustralasian Aluminium SmeltingTechnology conference has been set. Theprogramme organisers promise delegatesa week filled with up-to-date technicalinformation, research findings andvigorous panel discussions on technicalissues of concern to the industry. Thesesessions will be led by the world’s foremostexponents of smelting know-how, sodelegates will again have access to thegame-changers in the industry, as well asan exclusive opportunity to see up closethe very latest in operating smeltingtechnology.

Throughout the 33 years of thisboutique conference there has alwaysbeen a strong link between the UAE andAustralasia – including conjointdevelopment of technology and workpractices. With the changing dynamics ofthe Aluminium smelting industry it wasconsidered an appropriate occasion tobroaden this year’s “Australasian”

Conference to an “Austral-Asian” one andtherefore it is being held in the UAE.

Jebel Ali Golf & Beach Resort, located aconvenient distance from both DUBAL andEMAL smelters, has been selected as thevenue for the 11AASTC so that delegatescan visit the new state-of-the art Phase 2potline at EMAL. A limited groupaccommodation booking has also beenmade at the venue. Registration is opennow. Limited sponsorship opportunitiescan be arranged to promote your

organization at this major event.Conference and social event registration,accommodation bookings and sponsorshipopportunities are available on11AASTC.com. Detailed information aboutthe conference themes and submission ofabstracts and papers can also be obtainedfrom the website. �

ContactsPhil Black: [email protected] Skyllas-Kazacos: [email protected]

59www.aluminiumtoday.com EVENTS


11th Australasian Aluminium SmeltingTechnology Conference

Photo from the 10th AASTC in Launceston, Tasmania 2011

6-11th December 2014, Jebel AliGolf & Beach Resort, Dubai, UAE


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Dr. Ravi Yellepeddi, based in Switzerland, is the Global Director ofMarketing and Business Development, Materials and Minerals atThermo Fisher Scientific. He is responsible for product development,applications and technical marketing activities for Thermo Scientific on-lineprocessing and laboratory analysers in industrial applications, such as metals,cement, minerals, petrochemicals and material science.

1. How are things going at ThermoFisher Scientific?

It is an exciting time right now. Werecently launched our Thermo Scientific™ARL iSpark™ OES based ElementalAnalyser. It represents the next generationof elemental analysis with more flexibilitythan our previous models, yet retains theaccuracy and reliability customers expect.Later this year, we will also release a new IRbased sensor for the measurement ofcoatings on flat sheet. This sensor willcompliment the full array of non-contactdimensional sensors already available toaluminium sheet producers.

2. What are your views on thecurrent state of the globalaluminium industry?

As part of an integrated globalorganisation, we are always impressed withthe drive to maximise the potential ofaluminium. Recently, the drive to increasefuel economy in motor vehicles has resultedin some high profile opportunities foraluminium producers. The aviation industryalso continues to consume a wide variety ofaluminium products. Along with the ever-growing number of annual air passengers,we expect positive market conditions forboth the near and long term.

3. In your opinion, what are thebig issues affecting the aluminiumindustry today?

Access to low cost energy is alwaysan important issue to aluminiumproducers, as is the need to differentiatetheir product in the marketplace. Theability to supply a product with theconsistent chemistry required for themechanical properties and uniformdimensions also makes a big difference toaluminium consumers. If they perceive anyconcerns, they will find another supplier inthe market.

4. Where in the world are youbusiest at present?

With our base of operations inEurope, corporate headquarters in the US,and service and sales facilities in 29

countries around the world, we see activityin many areas. However, China continuesto be the area of largest growth.

5. What products are proving themost lucrative?

Each of our products bringsexceptional value to our customers. Whenour partners do well, we are able to sharein that success through repeat business,product support agreements and otheraftermarket services.

6. How quickly has Thermo FisherScientific responded to ‘greenpolitics’?

Our vision has always been to enableour customers to make the world healthier,cleaner and safer. Thermo Scientificproducts provide essential processinformation to reduce raw material waste,optimise production parameters andassure quality standards are met the firsttime. Aluminium producers are able torealise not only material savings, butenergy and waste stream managementsavings as well.

7. What are the big trends invalue-added production and where isThermo Fisher Scientific leading theway?

For commodity products, value isfound in consistency and profitabilitydepends on high-speed production andoverall mill yield. Our high-speed X-raygauges provide real-time feedback signalsfor sheet thickness control and ourautomated elemental analysers assureconsistent sample preparation andhandling, which in turn assures consistentproduct quality.

8. Where do you see the mostinnovation in terms of productiontechnologies – primary, secondary, orfurther downstream?

Application engineers seem to findnew uses for aluminium on a daily basis.While this often requires some out-of-the-box vision, the innovation often falls to themetallurgist to make vision a reality. I once

read that early metallurgists were reveredas magicians for their ability to manipulateearth and fire to create materials withextraordinary properties. The royalty duringthose times would take extraordinarymeasures to keep secret any newdevelopments within their kingdoms.While the fundamentals of aluminiumproduction are well known, thosecompanies still guard those secrets closely.

9. Do you see Thermo FisherScientific as an innovator within theindustry?

Absolutely. Our elemental analysersare often the first to see the newestmetallurgical “magic trick”. Thepartnership we have with many of ourcustomers leads them to contact us whenthey need a measurement solution.

10. Are there any research anddevelopment projects in place?

Certainly, but like the royalty oflong ago, we’ll keep those secrets wellguarded.

11. How do you view ThermoFisher Scientific’s development overthe short-to-mid term in relation tothe global aluminium industry?

Thermo Fisher Scientific is anoptimistic company. Our opportunities fordevelopment and growth are well alignedwith the markets we serve. The upsidepotential for aluminium growth inautomobiles, aerospace and other newmarkets will also translate to growth forus.

12. What does Thermo FisherScientific have in store for 2014?

We have invested in acomprehensive cross-training programmeto provide deep local product andapplications expertise to our installed base.As we continue to roll out our innovativeproducts, customers can expect theirThermo Scientific service engineer todeliver the same focus and dedication asthe physicists and engineers of ourresearch and application teams. �

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