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Special 2007
The international
smelting industry
Alcoa image - used with permission

Positive mood in the

German aluminium
industry

Strapping technology
with PET high per-
formance strip

Volume 83 January / February 2007

International Journal for Industry, Research and Application 1/2
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Die erste Ausgabe der ALUMINIUM
unter neuer redaktioneller Leitung
und dann gleich in einem neuen
Look: Das knnte schnell auch als
inhaltlicher Bruch mit der bisherigen
Tradition der Zeitschrift interpretiert
werden, doch wre dies ein Missver-
stndnis.
Der langjhrige Chefredakteur
Dr.-Ing. Peter Johne hat die ALUMI-
NIUM in den vergangenen mehr als
zehn Jahren zu einer international
renommierten Fachzeitschrift entwi-
ckelt, die sich durch fundierte und gut
Volker Karow recherchierte Berichte aus Industrie,
Chefredakteur Forschung und Praxis auszeichnet.
Editor in Chief Diese Prgung, das ist der Anspruch,
soll natrlich fortgesetzt werden. Da-
bei liegt es in der Natur der Sache,
dass ein gelernter Volkswirt einen
etwas anderen Blickwinkel als ein
Ingenieur hat. Das mag hier und da
mit einer leichten inhaltlichen Ak-
pro domo: zentverschiebung einhergehen, doch
bleiben technische und wissenschaft-
Kontinuitt im liche Beitrge auch knftig zentrale
Bausteine der ALUMINIUM. Die neue
Wandel Chefredaktion wei sich dabei glck-
lich, auf die Expertise des geschtzten
Kollegen zurckgreifen zu knnen.
Dr. Johne wird dieser Zeitschrift wei-
terhin zur Verfgung stehen: als Autor
und auch als Herausgeber.
Was nun die berarbeitung des
pro domo: Layouts betrifft: Der Leser wird beim
Durchblttern der neuen Ausgabe
Change with feststellen, dass der Anteil der far-
bigen Seiten erweitert wurde. Bei ge-
continuity nauerem Hinsehen wird erkennbar,
dass Struktur und Gliederung der
ALUMINIUM mit Blick auf bersicht-
lichkeit und Leserfhrung berarbei-
tet wurden. Auch hinsichtlich der
Zweisprachigkeit von Artikeln waren
Herausgeber und Redaktion bestrebt,
aus Lesersicht Optimierungen vorzu-
nehmen. Zu guter Letzt ging es auch
darum, die Zeitschrift layouttech-
nisch abwechslungsreicher zu gestal-
ten. Wir hoffen, dies ist uns gelungen
und der geneigte Leser sieht in der
berarbeitung einen Gewinn.
Jenseits gestalterischer Neuerun-
gen bleibt die ALUMINIUM auch
knftig eine die Branchenwelt abbil-
dende Fachzeitschrift und den sich
daraus ergebenden Anforderungen
verpflichtet.
ALUMINIUM 1-2/2007
EDITORIAL
One of the first things that will be
noticed about this first issue of ALU-
MINIUM under its new editorial man-
agement, is a new look. That might at
first sight also lead to the expectation
of a break from the previous tradition
of the journal in terms of content, but
this would be a misunderstanding.
Dr.-Ing. Peter Johne, Editor in
Chief of ALUMINIUM for very many
years, developed it over much more
than a decade into an internation-
ally renowned technical journal dis-
tinguished for its authoritative and
well-researched reports on industry,
research and practical applications.
Naturally, we aim to maintain that
reputation and image. It is only to be
expected, however, that a trained po-
litical economist will see matters from
a viewpoint somewhat different from
that of an engineer. Here and there this
may result in a slight shift of empha-
sis in the content, but technical and
scientific contributions will as always
remain cornerstones of ALUMINIUM
in the future as well. The new Chief
Editor is only too happy to make the
most of the expertise of his esteemed
colleague Dr. Johne, who will still lend
his services to this journal, both as an
author and as publisher.
As regards the redesigned layout:
readers leafing through the new is-
sue will note that the proportion of
coloured pages has been increased.
Careful observation will show that the
structure and organisation of ALU-
MINIUM have been modified with
a view to greater clarity and reader
guidance. In relation to the bilingual
presentation of articles as well, the
publisher and editor have striven to
achieve optimisations from the read-
ers standpoint. Last but not least, some
further changes have had to be made
in order to provide greater variety in
the technical layout of the journal.
We hope that we have managed this
successfully and that sympathetically
inclined readers will find the changes
beneficial. Notwithstanding its new
design features, ALUMINIUM will in
the future too remain a journal that
faithfully portrays the world of the
aluminium branch and does all that
is necessary to fulfil the responsibility
of doing so.
3
I N H A LT
16
30
0 Hydro vollendet Metallkreislauf in Neuss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Neue Redaktionsanschrift
New editorial office
Volker Karow
Franz-Meyers-Strae 16
D-53340 Meckenheim
Tel: +49(0)2225/8359643
Fax: +49(0)2225/18458
E-Mail: vkarow@online.de
4 ALUMINIUM 1-2/2007
EDITORIAL
pro domo: Kontinuitt im Wandel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A KT U E L L E S
Personen, Unternehmen, Mrkte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WIRTSCHAFT
Aluminiumpreise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Produktionsdaten der deutschen Aluminiumindustrie . . . . . . . . . . . . . . . . . . 14
Die deutschen Httenbetriebe: technisch effizient, umweltpolitisch
vorbildlich und ein wichtiges Glied in der Wertschpfungskette . . . . . 16
European Coil Coating Kongress: Marktentwicklung, Technologie-
trends, Gesetzgebung ................................................................. 20
S P E C I A L 2 0 0 7: D I E I N T E R N AT I O N A L E
A L U M I N I U M - H T T E N I N D U S T R I E . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I N T E R N AT I O N A L E B R A N C H E N N E W S . . . . . . . . . . . . . 62
M A R KT U N D T E CH N I K
Signode: Umreifungstechnik mit PET-Hochleistungsband . . . . . . . . . . . . . . 70
Alcutec Engineering rstet russische Umschmelzhtte aus . . . . . . . . . . . . 75
Deutsche Aluminiumkonjunktur luft derzeit rund . . . . . . . . . . . . . . . . . . . . . . 78
Audi fr innovatives Karosseriekonzept ausgezeichnet . . . . . . . . . . . . . . . . 84
Kolbenschmidt Pierburg setzt auf AGR-Khler aus Aluminium. . . . . . . . 86
M A R K T B E R I C H T: A L U M I N I U M I M B A U W E S E N
Energieeffizientes Bauen im Fokus von Politik und Wirtschaft . . . . . . . . 88
bergeordnete Trends im Fenster- und Fassadenbau . . . . . . . . . . . . . . . . . . 89
Europischer Architektur-Wettbewerb von Corus Bausysteme ......... 90
Fenstermarkt im Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Grtes deutsches Broprojekt mit Wicona-Fassaden .................... 91
RECYCLINGINDUSTRIE
Vorbericht: 9. Internationaler Aluminium Recycling Kongress der OEA 92
FORSCHUNG
Rhrreibschweien von artungleichen Aluminiumknet-
und -druckgusslegierungen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
V E R A N S TA LT U N G E N
22 nd ASK Metal Forming, Termine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fortbildung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
BDI-Umweltpreiswettbewerb 2007/08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
D O K U M E N TAT I O N
Neue Bcher .......................................................................... 105
Firmenschriften . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Literaturhinweise .................................................................... 107
Patente ................................................................................... 109
Impressum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Vorschau ................................................................................ 130
B E Z U G S Q U E L L E N V E R Z E I C H N I S . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
 CONTENTS

EDITORIAL
pro domo: Change with continuity ........... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

NEWS IN BRIEF
People, companies, markets ................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ECONOMICS
European Coil Coating Congress: market development,
technology trends, legislation ................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The Russians are coming: example Rusal .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydro maintains speed in aluminium repositioning . . . . . . . . . . . . . . . . . . . . . 26
Global roll-out of breakthrough Novelis Fusion technology . . . . . . . . . . 27
Alcoa joint venture with Sapa group ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

S P E C I A L 2 0 0 7: T H E I N T E R N AT I O N A L
A L U M I N I U M S M E LT I N G I N D U S T R Y
Almeq electric preheater for cathode blocks ................................. 30
Alprg: a software tool for aluminium smelting .............................. 32
Vittorio de Nora honoured by ECS ............................................... 36
Aumund cooling conveyor for hot bath material ............................ 38
Advances in gas suspension calcination technology ........................ 40
Anode rod repair and manufacture .............................................. 42
Integrated continuous billet processing ......................................... 44
De Nora inert metallic anode: further developments ...................... 48
Boron nitride plus binder a synonym for higher productivity ....... 53
Thyristor rectifiers for aluminium plants with advanced
free-wheeling control ........................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Moeller direct pot feeding technology ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
88
C O M PA N Y N E W S W O R L D W I D E
Aluminium smelting industry .................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Bauxite and alumina activities ................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Secondary aluminium smelting and recycling activities . . . . . . . . . . . . . . . . 66
Aluminium semis, Suppliers .................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
On the move...................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Inserenten
M A R K E TS A N D T E CH N O LO GY
dieser Ausgabe
Signode: strapping technology with PET high-performance strip . . . . 70
Alcutec: German know-how for Russian recycling complex . . . . . . . . . . . 74 List of advertisers
Positive mood in the German aluminium industry . . . . . . . . . . . . . . . . . . . . . . 78 ABB AG, Schweiz 51
GDA participation at UN conference on sustainability . . . . . . . . . . . . . . . . . . 80 Alcutec Engineering GmbH 93
EAA launches new sustainability development indicator results . . . . . . 81 Bhler Edelstahl GmbH, sterreich 23
Russias packaging market: aluminium processing technology at Buss ChemTech AG, Schweiz 65
the forefront ...................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 BWG Bergwerk- und Walzwerk-
Audi takes award for innovative TT body concept . . . . . . . . . . . . . . . . . . . . . . 84 Maschinenbau GmbH 13
Kolbenschmidt Pierburg successfully marketing its EGR system . . . . . . 86 Coiltec Maschinenvertriebs GmbH 27
Recent advances in coil coating technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Drache Umwelttechnik GmbH 81
Dovebid, USA 63
Edimet SpA, Italien 11
RECYCLING INDUSTRY
Glama Maschinenbau GmbH 15
Preview of the 9 th International Aluminium Recycling Hartmann Frderanlagen GmbH 57
Congress of the OEA ............................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Hertwich Engineering GmbH, sterreich 02
High Performance Industrie-Technik GmbH,
EVENTS sterreich 17
Dates, 22 nd ASK Metal Forming: Forming the Future . . . . . . . . . . . . . . . 102 Innovatherm Prof. Dr. Leisenberg
GmbH + Co. KG 37
D O C U M E N TAT I O N Inotherm Industrieofen- und
Wrmetechnik GmbH 22, 78
New books ............................................................................. 105
Moeller Materials Handling GmbH 61
company brochures .................................................................. 106 Moltech Sytems Ltd., Schweiz 132
Literature service ................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Padelttherm GmbH 55
Imprint ..... ........................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Precimeter Control AB, Schweden 19
Preview .... ........................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Bruno Presezzi Officine Meccaniche, Italien 59
SMS Demag AG 131
S O U R C E O F S U P P LY L I S T I N G .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

ALUMINIUM 1-2/2007 5
 AKTUELLES

Aluminiumbranche vor groen Herausforderungen

GDA-Prsident Gerhard Budden-
baum (Foto) auf der Jahrespresse-
konferenz des Gesamtverbandes der
Aluminiumindustrie im November
2006: Die Aluminiumindustrie ist
heute, mehr noch als viele andere
Branchen, ein internationales, globa-
les Geschft. Rohstoffe, Httenstand-
orte, Verarbeitungsstandorte und
Verbrauch sind breit gestreut und zu-
nehmend eng miteinander vernetzt.
Unsere Branche steht vor hohen
Herausforderungen. Dass man auch
in Deutschland produzieren kann,
beweist die Aluminiumindustrie seit
Jahren, allerdings insbesondere bei
GDA
Dem Wettbewerbsdruck der Niedrig-
lohnlnder setzen unsere Unterneh-
men ein hohes Qualittsniveau,
absolute Zuverlssigkeit und groe
Flexibilitt entgegen. Die europische
Aluminiumindustrie wird sich nur
durch ihre eigene Innovationskraft
langfristig an den Mrkten behaup-
ten. Nur wenn sich die Branche auf
die Herstellung von Produkten kon-
zentriert, die Marktnhe brauchen,
eine hohe Wertschpfung aufweisen
und viel Know-how und gut ausge-
bildetes Personal verbunden mit ho-
hen Serviceleistungen bentigen, hat
Europa als Produktionsstandort eine

Produkten mit hoher Wertschpfung. Zukunft. (s. S. 78f)

Bundeswirtschaftsminister Michael Glos

trifft Vertreter der NE-Metallbranche
Bundeswirtschaftsminister Michael
Glos hat gegenber Vertretern der
deutschen und europischen NE-
Metallindustrie auf die Bedeutung
der Leicht- und Buntmetalle fr den
technologischen Fortschritt und den
Exporterfolg der deutschen Wirt-
schaft hingewiesen. Deutschland und
die EU brauchen nach Ansicht des
Ministers auch in Zukunft eine ge-
schlossene Wertschpfungskette bei
der Erzeugung und Verarbeitung von
Aluminium, Kupfer, Zink und den an-
deren NE-Metallen. Besonders fr die
Autoindustrie und die Luftfahrt seien
sie von steigender Bedeutung.
Energiepolitik ist nach Aussage
des Ministers ein wichtiger Bau-
WVM
stein, um Deutschland international
wettbewerbsfhig zu halten. Er un-
terstrich die Bedeutung internatio-
nal wettbewerbsfhiger Strompreise
und funktionierender nationaler und
europischer Mrkte fr die energie-
intensive Industrie. ber die ange-
spannte Lage auf den internationalen
Rohstoffmrkten msse man im Rah-
men der Rohstoff- und Handelspolitik
intensiv sprechen, so Glos. Es gehe
darum, Handelshemmnisse zu besei-
tigen und alle politischen Instrumente
zu nutzen, um zu einem zu gleichen
Bedingungen funktionierenden Roh-
stoffmarkt zu kommen.
WVM-Prsident Ulrich Grillo
verdeutlichte zusammen mit natio-
nalen und internationalen
Vertretern der NE-Metal-
lindustrie die zentralen
Herausforderungen der
im globalen Wettbewerb
stehenden Branchenun-
ternehmen. Neben der En-
ergie- und Rohstoffpolitik
gehre hierzu ein Umwelt-
und Klimaschutz, der das
tungen der Nachhaltigkeit, erwarte
aber zugleich bei allem politischen
Handeln die Gleichrangigkeit von
konomie, kologie und Sozialem.
Trimet
M. Rosenbaum neuer
Automotive-Vorstand
Matthias Rosenbaum ist neuer Vor-
stand des Geschftsbereichs Auto-
motive bei der Trimet Aluminium AG.
Er bernimmt die Verantwortung der
Werke in Harzgerode (Sachsen-An-
halt) und Smmerda (Thringen) und
folgt damit auf Uwe Prnger, der den
Geschftsbereich sechs Jahre geleitet
hat.
Rosenbaum, geboren in Reckling-
hausen, studierte an der RWTH Aa-
chen Elektrotechnik. Bevor er im
Herbst 2006 zur Trimet wechselte,
war er unter anderem fr die Moto-
rola AIEG (Automotive and Industrial
Electronics Group), als Sprecher der

industrielle Engagement Geschftsfhrung der KS Kolben-

v.l.n.r.: Guy Thiran, Geschftsfhrer Eurometaux; Martin und die internationale schmidt GmbH und als European
Kneer, Hauptgeschftsfhrer WVM; Bundesminister fr Wettbewerbsfhigkeit be- Sales Manager bei General Motors
Wirtschaft und Technologie, Michael Glos; Ulrich Grillo,
Vorstandsvorsitzender Grillo-Werke AG; Javier Targhetta, rcksichtige. Die Industrie Delco Remy ttig. Matthias Rosen-
Geschftsfhrer Atlantic Copper S.A. stehe zu den Verpflich- baum ist 52 Jahre alt.

6 ALUMINIUM 1-2/2007
 NEWS IN BRIEF

Alcoa appoints President V. de Nora Norsk Hydro top focus

of Flexible Packaging honoured by ECS on aluminium

Alcoa has named Jeff Kellar President Vittorio de Nora has been honoured as
of its Alcoa Flexible Packaging busi- the recipient of The Electrochemical
ness, succeeding Bimal Kalvani. Kel- Society (ECS) 2006 Edward Goodrich
lar joins Richmond, Virginia-based Acheson Award. The award was es-
Alcoa Flexible Packaging from Tetra tablished in 1928 to recognise distin-
Pak of Chicago, where he was Vice guished contributions which advance
President of strategic development objects, purposes or activities of ECS.
and marketing. De Nora has dedicated his career to
scientific research in the field of elec-
Aston Martin
trochemistry, in-
cluding in partic-
ular the fields of
chlorine-alkali
and aluminium
production. His
research achieve-
ments centre on
his efforts to find
a feasible inert an-
ode. More about
de Noras career
on page 36 of this
issue.
The Aston Martin V8 Vantage Roadster was revealed at the 2006 Los Angeles Auto
Show end of November. The Roadster shares the unique-to-Aston Martin bonded
aluminium VH (Vertical Horizontal) architecture the backbone to all modern Aston
Martins. Adding to this structure sophisticated materials such as lightweight alloys,
magnesium and advanced composites are used for the body, further contributing to
the cars low weight and high rigidity. Body specification: Aluminium alloy, steel, com-
posite, and magnesium alloy body. Extruded aluminium side impact bars and integral
rollover bars. Suspension: Independent double aluminium wishbones, coil over alumi-
nium monotube dampers and anti-roll bar.
Hydro will focus on aluminium fol-
lowing the US$ 30 billion takeover of
its oil and gas assets by Statoil. Fol-
lowing the completion of the recom-
mended merger, Hydro will be the
worlds third-largest listed alumin-
ium company and is expected to be
the fourth-largest company listed on
the Oslo Stock Exchange in terms of
market capitalisation. The company
will continue to focus on its high per-
forming primary production system
and well-developed casthouse and
remelter system in Europe and the
United States. It will also pursue new
alumina and metal growth opportuni-
ties in attractive areas.
Novelis with new CEO
Novelis has named Edward A. Blech-
schmidt, a member of its Board of
Directors, to become Acting Chief
Executive Officer, effective January
2, 2007. Mr. Blechschmidt succeeds
Board Chairman William T. Mona-
han, who has been Interim CEO since
August 2006. Mr. Monahan remains
Chairman of the Novelis Board. Nov-
elis will continue its search for a per-
manent CEO.

Shell Lubricants with new rolling oils production facility

Shell Lubricants have opened a
state-of-the-art rolling oils produc-
tion facility in Dortmund, Germany
to develop and produce rolling oils,
thus incorporating proven Control-
led Particle Size (CPS) technology to
meet the increasing demands of the
metals industry. This new facility will
enable Shell lubricants companies
to provide a one-stop-shop for the
metals industry, offering high quality
factory plant maintenance lubricants,
speciality greases and rolling oils, on
a global basis.
well as producing Croda specification
rolling oils, the new facility will house
a product development team that will
continue to upgrade and extend the
rolling oils portfolio.
The production of rolling oils at the
new facility is proof of Shells com-
mitment to the metals industry. In the
last 12 months, Shell Lubricants have
introduced a number of products
aimed at helping metals operators
to increase productivity and reduce
downtime. In addition to the one-
stop-shop range of lubricants, metals
Shell Lubricants

Following the acquisition of Croda operators will in future be able to ben-

Chemicals Internationals (CCI) roll-
ing fluid and production engineer-
ing business in January 2006, Shell
Lubricants have now successfully
integrated CCIs range of rolling oils
into their metals product portfolio. As
efit from having access to Shell lubri-
cants experts at a local level to assist
in reducing downtime and increasing
Roger Moulding (left) and Peter Rommers-
productivity, said Roger Moulding, kirchen from Shell Lubricants inaugurating
Vice President Specialities for Shell production of rolling oils in Dortmund,
Germany
Lubricants .

ALUMINIUM 1-2/2007 7
 AKTUELLES
Mikrochip-Forschung
Aluminium lsst Nanodrhte wachsen
Max-Planck-Institut
Eingefrbte Aufnahme von
Silizium-Nanodrhten ( 40 nm).
Silizium-Nanodrhte knnen helfen,
Mikrochips weiter zu verkleinern.
Wissenschaftler des Max-Planck-In-
stituts fr Mikrostrukturphysik in
Halle haben nun erstmals einkristal-
line Silizium-Nanodrhte gezchtet,
die wichtige Voraussetzungen dafr
erfllen: Sie haben Aluminium als
Katalysator verwendet, um die Na-
nodrhte wachsen zu lassen. Bislang
setzten Wissenschaftler zu diesem
Zweck vor allem Gold ein. Doch
schon Spuren des Edelmetalls beein-
trchtigen die Funktion von Halblei-
terbauteilen drastisch.
Aluminium dagegen beeintrchtigt
die Chipeigenschaften nicht und lsst
im Gegensatz zu anderen Metallen
schon bei relativ niedriger Tempe-
ratur von rund 450 C Silizium-Na-
nodrhte von besonders hoher Quali-
tt sprieen - eine Voraussetzung, um
die Kosten des Prozesses zu begrenz-
en. Das neue Verfahren erfllt die
wichtigsten Bedingungen, um Silizi-
um-Nanodrhte industriell einsetzen
zu knnen, erluterte Stephan Senz,
einer der beteiligten Wissenschaftler.
Um Aluminium in so kleine Par-
tikel zu zerlegen, dass sich an ihm
die feinen Drhte bilden, erhitzen die
Forscher eine dnne Schicht davon
auf einer Silizium-Unterlage. Die Folie
zerreit dann in lauter winzige Teil-
chen. Anschlieend gehen die Wis-
senschaftler wie in schon bekannten
Verfahren vor: Sie dampfen Silan, ein
siliziumhaltiges Gas, auf die Oberfl-
che, das sich am Katalysatorpartikel
in elementares Silizium umwandelt.
Das Silizium lst sich daraufhin in
8 ALUMINIUM 1-2/2007
dem Aluminium-Teilchen. Wenn
dieses kein weiteres Silizium aufneh-
men kann, kristallisiert es an der Un-
terseite des Partikels wieder aus. So
wchst ein einkristalliner Silizium-
Nanodraht von etwa 40 Nanometern
Durchmesser heran, der an der Spitze
ein Katalysatorteilchen trgt.
Die viel versprechende Forschung
an Halbleiter-Nanodrhten bewegt
sich an der Schnittstelle von Grund-
lagenforschung und technischer An-
wendung. Neben ihrem denkbaren
Einsatz in der Halbleiterindustrie
sind die Nanodrhte sehr interessant
fr die physikalische Grundlagenfor-
schung, da ber ihre Eigenschaften
und ihr Wachstum noch nicht viel
bekannt ist, so Senz.
Neuer Airbus A350 mit CFK-Auenhaut
Um die Kerosin- und Wartungsko-
sten zu reduzieren, wird der Flug-
zeugrumpf des neuen Airbus A350
XWB erstmals mit kohlefaserverstrk-
ten Kunststoffen anstelle von Alumi-
nium ausgestattet. Die Flugzeugzelle
Bundesumweltministerium fr-
dert innovative Recyclinganlage
Bundesumweltminister Sigmar Gabriel
untersttzt die Errichtung eines innovativen
Schmelzofens zur Herstellung von Kupfer in
Osnabrck. Die KM Europa Metal AG plant,
einen bisher nur in der Aluminiumindustrie
eingesetzten kippbaren Drehtrommelofen
zu modifizieren und zum energieeffizien-
ten Schmelzen und Raffinieren von Kupfer
einzusetzen. Das Vorhaben wird vom
Bundesumweltministerium mit rund 1,3
Millionen Euro aus dem Umweltinnovati-
onsprogramm gefrdert.
Fortschritte bei der Energieeffizienz
in energieintensiven Industrien tragen
in besonderem Mae zum Erreichen der
Emissionsminderungsziele bei den Treibh-
ausgasen bei, so Gabriel. Die Durchfh-
rung des Vorhabens sei jedoch nicht nur
Leserreise zur
Expo Aluminio
Eine Leserreise der Extraklasse: Der
Giesel Verlag, Isernhagen, organisiert in
Zusammenarbeit mit Reed Exhibition in
der Zeit vom 20. bis 25. Mai 2007 einen
Besuch der Expo Aluminio in Sao Paulo
(22. bis 24. Mai). Auf dem Business-
Programm stehen der Messebesuch so-
wie Besuche bei brasilianischen Alumini-
umunternehmen. Eine gute Gelegenheit,
Kontakte zu wichtigen Firmen und Be-
hrden zu knpfen. Ein Flug nach Rio de
Janeiro mit Stadtrundfahrt und Besuch
von Zuckerhut oder Christusstatue auf
dem Corcovado runden das Programm
ab. Neugierig geworden? Detailfragen
beantwortet Jutta Illhardt, Tel: 0511 /
7304-126, Fax: 0511 / 7304-157, E-Mail:
Illhardt@giesel.de.
wird zu ber 60 Prozent aus neu
entwickelten Werkstoffen bestehen.
Die Aufnahme des Flugbetriebs des
neuen A350 XWB ist fr das Jahr 2013
vorgesehen.
gut fr die Umwelt, sondern aufgrund der
Energieeinsparung auch aus wirtschaftlicher
Sicht attraktiv.
Im Rahmen des Vorhabens soll erstmals
ein kippbarer Drehtrommelofen aus der
Aluminiumindustrie zum Schmelzen und
Raffinieren von Sekundrkupfer eingesetzt
werden. Der neue Ofen verfgt im Gegen-
satz zu den bisher in der Kupferindustrie
eingesetzten Drehtrommelfen ber nur
eine ffnung. Dadurch knnen Abgase op-
timal erfasst und diffuse Emissionen auf ein
Minimum reduziert werden. Zudem wird
eine verbesserte Energieausnutzung gegen-
ber beidseitig offenen Drehtrommelfen
erreicht. Im Vergleich zu den bisherigen
Verfahren werden 10 bis 20 Prozent Ener-
gie eingespart.

Raw material prices remain high
According to the branch report of IKB
Deutsche Industriebank, the develop-
ment of international raw material
prices has now exceeded its all-time
high. Decisive for further price devel-
opment will be above all the future
trade environment. Owing to the rela-
tively stable boundary conditions of
the world economy it is unlikely that
in the medium term there will be any
appreciable downturn in the demand
for raw materials.
The increasing access of develop-
ing countries, above all China, to raw
material reserves will further boost
worldwide needs and therefore also
maintain prices at a relatively high
level. This applies to steel and NF
metals such as aluminium as much as
to oil and natural gas. All in all, it can
be assumed that for metallic and also
energy raw materials the low prices
of the mid-1990s and the beginning
of the present decade will for the time
being not recur. As regards the price
Giesel Verlag bernimmt APT International
und APT News
Der Giesel Verlag aus Isernhagen bei
Hannover, Verlagsheimat dieser Zeit-
schrift, hat zum 1. Januar 2007 die
beiden Publikationen APT Internati-
onal und APT News bernommen.
Durch die Akquisition wird die vor-
handene umfassende Zeitschriften-
reihe im Werkstoffbereich erweitert,
so Dietrich Taubert, Geschftsfhrer
des Giesel Verlags. Gleichzeitig ent-
steht durch die Bndelung der Krfte
ein Verlag mit sehr groem Potenzial
im Aluminiumbereich. Taubert: Mit
unserem Angebot an hochwertigen
Publikationen knnen wir die Markt-
bedrfnisse der Aluminiumbranche
auf den internationalen Mrkten be-
dienen.
Der Giesel Verlag gibt mit den be-
stehenden Zeitschriften ALUMINI-
UM International Journal, Alumini-
um Praxis, METALL International
Journal sowie Composite Materials
und Automotive Materials europa-
weit fhrende Werkstoff-Fachpublika-
tionen heraus. Durch die Integration
ALUMINIUM 1-2/2007
NEWS IN BRIEF
New Airbus A350
level of aluminium, IKBs Research De- With CFRP panelled
partment expects a medium-term de- fuselage skin
velopment within the range between
2,000 and 2,500 US$/t. In the medium To set new standards in fuel-efficien-
term the worldwide enlargement of cy and maintainability the new Airbus
electrolysis capacities will relieve the A350 XWB will feature the latest in-
situation. IKB also assumes that specu- novations in terms of advanced tech-
lative demand for aluminium by hedg- nologies. Amongst those is the use of
ing funds will not increase further. all-new, easy to maintain and much
Assuming a slight slowdown of lighter Carbon Fibre Reinforced Plas-
the world economy, IKB in any event tic panelled fuselage skins instead of
expects a sideways movement of alu- aluminium.
minium demand. There is unlikely to This innovation in manufacturing
be an appreciable fall in consumption permits easier maintainability and
in the future. The worldwide trend to- reparability of individual airframe
wards lightweight construction in the parts, while also allowing the struc-
transport sector (automotive, aviation), ture of the panels to be much better
the growing need for packaging and the optimized in terms of design to the
recovery of the building economy in stress and load requirements of each
Europe will be major driving forces. individual airframe part. Over 60 per
In the automotive industry alumin- cent of the airframe will be made of
ium and plastics are seen as the most new materials.
important materials for reducing en- Entry into service of the first A350
ergy consumption and for meeting the XWB is planned for 2013.
objectives of the Kyoto protocol.
der beiden APT-Zeitschriften sind erluterte Travis. ber eine Vernet-
wir weltweit optimal aufgestellt und zung mit den bisherigen Titeln des
knnen global agierenden Kunden die Giesel Verlags ergeben sich fr Leser
passende redaktionelle und Werbe- und Anzeigenkunden sprbare Sym-
Plattform bieten, sagte Taubert. biosen hinsichtlich Inhalt und Marke-
John Travis wird weiterhin als tingmglichkeiten.
Chefredakteur
der APT-Medien
ttig sein. Der
Giesel Verlag
verantwortet Ver-
trieb, Anzeigen-
akquisition und
Produktion. Die
Fokussierung auf
die redaktionelle
Ttigkeit und die
Integration in die
Strukturen eines
fhrenden Fach-
verlags sind wich-
tige Schritte bei
der konsequen-
ten Weiterent-
wicklung dieser
Zeitschriften, John Travis (l.) und Dietrich Taubert
9
AKTUELLES
Seit dem Jahr 2000 haben sich die Industriestrompreise mehr als verdoppelt
Deckelung der Energiekosten beschlossen
Stromintensive Unternehmen wie Alu-
miniumhtten werden 2007 erneut
bei ihren Energiekosten entlastet. Be-
gnstigt sind laut Bundesumweltmi-
nisterium rund 330 Firmen des pro-
duzierenden Gewerbes, die um rund
345 Mio. Euro entlastet werden. Im
Auftrag des Bundesumweltministeri-
ums hat das Bundesamt fr Wirtschaft
und Ausfuhrkontrolle (BAFA) Ende
Dezember 2006 ber die Antrge
nach der besonderen Ausgleichsre-
gelung des Erneuerbaren-Energien-
Gesetzes (EEG) entschieden und zum
Jahreswechsel die entsprechenden
Bescheide versandt. Durch eine zum
1. Dezember 2006 in Kraft getretene
Stromvertrag fr Hamburger
Aluminiumhtte perfekt
Die Trimet Aluminium AG und der Strom-
versorger RWE haben sich auf einen neuen
Stromliefervertrag fr die Aluminiumhtte
in Hamburg (ehemals HAW) geeinigt.
Der Vertrag hat ein Volumen von 2 TWh
pro Jahr und gilt von 2008 bis minde-
stens 2010. Trimet plant die schrittweise
Wiederinbetriebnahme ab April 2007. Die
Produktion soll 2008 wieder in vollem
Umfang laufen. Der Anfahrbetrieb im Jahr
2007 wird ber flexible, kurzfristige Strom-
kontrakte sichergestellt. Der Liefervertrag
nutzt alle Mglichkeiten der liberalisierten
Grohandelsmrkte und kombiniert
10
nderung des EEG fllt die Entlastung
deutlich hher als bisher aus. So be-
trgt die so genannte EEG-Umlage der
besonders stromintensiven Unterneh-
men knftig nur noch 0,05 ct/kWh.
Die rckwirkende Anwendung der
Neuregelung ab dem 1. Januar 2006
hat fr die begnstigten Unterneh-
men zustzlich einen Wert von etwa
80 Mio. Euro. Im Antragsverfahren fr
2007 hat BAFA eine zu privilegieren-
de Strommenge von insgesamt 72.040
GWh ermittelt, die nicht mit vollem,
sondern begrenztem EEG-Anteil ab-
zunehmen ist. Hiervon entfallen etwa
94 % (67.826 GWh) auf Unternehmen
des produzierenden Gewerbes.
verschiedene innovative Stromprodukte.
So kommt das aus der Finanzwirtschaft
bekannte Optionsprodukt Multi Period
Extendible auch in der Energiewirtschaft
zur Anwendung. Es gewhrt dem Kunden
deutliche Preisvorteile in den frhen Lie-
ferphasen, whrend der Energieversorger
gegen Preisverfall in den spten Liefer-
phasen abgesichert ist. Auerdem ist der
von Trimet zu zahlende Strompreis an den
Aluminiumpreis gekoppelt. Des Weiteren
besteht die Mglichkeit, kurzfristig Lastab-
schaltungen vorzunehmen, die dem Strom-
versorger zustzliche Flexibilitt bieten.
82m cans recycled
The U.S. Conference of Mayors, Keep
America Beautiful, Inc. and Novelis
Inc. announced the winners in the
2006 Cans for Cash: City Recycling
Challenge on America Recycles Day.
For the third year, the program chal-
lenged like-sized cities to compete
against each other in aluminum can
collection for monetary awards and
to encourage recycling. During two
weeks in September 2006, more than
30 cities collected over 2.4 million
pounds of aluminum cans which
equates to over 82 million used bev-
erage cans. The aluminum can is the
countrys most recycled beverage
container and has been for more than
20 years. In 2005, more than 100 bil-
lion aluminum beverage cans were
produced in the United States and
52% of them were recycled (a 1.0% in-
crease over the previous year). Nearly
the same amount - close to 50 billion
cans or roughly US$ 1.5 billion worth
of aluminum - was lost to landfill.
Coperion bernimmt
Hartmann Frder-
anlagen
Mit Wirkung zum 1. Januar 2007 hat
die Coperion Waeschle Beteiligungs
GmbH die Geschftsaktivitten der
Hartmann Frderanlagen GmbH,
Offenbach, bernommen. Das Un-
ternehmen, ein fhrender Anbieter
im Schttguthandling von Tonerde,
wird innerhalb der Coperion-Grup-
pe in den Geschftsbereich Materials
Handling eingegliedert und knftig
als Coperion Hartmann firmieren.
Der Sitz der Gesellschaft und die Ar-
beitspltze der Mitarbeiter bleiben
erhalten. Eigentmer der Coperion
Gruppe ist die britische Private Equity
Gesellschaft Lyceum Capital. Coperi-
on Waeschle liefert fr die Kunststoff-
herstellung die gesamte Prozesskette
vom Reaktor bis zur Logistik. Erklrtes
strategisches Ziel von Coperion ist es,
auch in der Aluminiumherstellung
die komplette Prozesskette von der
Rohmaterialannahme ber das La-
gern und Transportieren bis zur Be-
schickung der Elektrolysezellen mit
Systemlsungen abzudecken.
ALUMINIUM 1-2/2007
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12 ALUMINIUM 1-2/2007
 


  






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WIRTSCHAFT

Produktionsdaten der deutschen Aluminiumindustrie

Primraluminium Sekundraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**
Produktion +/- Produktion +/- Produktion +/- Produktion +/-
(in 1.000 t) in % * (in 1.000 t) in % * (in 1.000 t) in % * (in 1.000 t) in % *
Okt 05 53,4 -6,0 61,2 5,9 153,1 9,4 43,2 0,9
Nov 51,1 -7,1 65,3 6,7 150,7 -0,9 47,3 9,2
Dez 47,6 -16,5 54,6 6,6 122,6 2,6 31,4 13,4
Jan 06 42,9 -24,8 65,4 16,2 136,2 -4,2 45,4 10,7
Feb 38,7 -25,5 65,1 9,6 145,5 5,8 46,0 8,6
Mrz 43,1 -24,8 78,9 27,1 160,1 6,1 51,9 22,0
Apr 42,4 -23,8 62,5 2,8 133,3 -12,9 42,8 -3,8
Mai 43,4 -24,0 68,0 22,1 154,4 5,2 49,7 21,8
Jun 43,2 -20,7 65,7 3,3 146,4 -2,4 47,8 0,1
Jul 45,1 -17,9 64,0 4,6 148,8 -5,2 48,5 9,3
Aug 45,2 -16,7 59,6 7,2 149,8 -6,0 48,1 9,1
Sep 42,8 -19,4 66,9 6,9 144,2 -8,8 51,1 9,2
Okt 44,1 -17,4 65,0 6,1 153,2 0,0 52,2 21,1
* gegenber dem Vorjahresmonat, ** Stangen, Prole, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie GDA, Dsseldorf

Primraluminium Sekundraluminium

Walzprodukte > 0,2 mm Press- und Ziehprodukte

14 ALUMINIUM 1-2/2007
WIRTSCHAFT
Die deutschen Aluminiumhtten
Technisch hoch effizient, umweltpolitisch vorbildlich
und ein wichtiges Glied in der Wertschpfungskette
Christian Wellner, Jrg H. Schfer, Dsseldorf
Die Konjunktur in Deutschland
entwickelte sich 2006 mit einer
Dynamik, wie sie lange nicht
mehr gesehen war. Selbst aus dem
Arbeitsmarkt kamen positive Mel-
dungen. Kurzfristig stellt sich die
Frage, inwieweit die jngste Erh-
hung der Mehrwertsteuer zu einem
konjunkturellen Dmpfer fhren
wird. Langfristig kann selbst die
gute Konjunktur des vergangenen
Jahres nicht darber hinwegtu-
schen, dass seit Anfang der 1990er
Jahre zwei Millionen industrielle
Arbeitspltze in Deutschland ver-
loren gegangen sind. Nach wie vor
wandern zahlreiche Unternehmen
mit Teilen ihrer Produktion ins
Ausland, weil die wirtschaftlichen
Rahmenbedingungen in unserem
Land erhebliche Wettbewerbsnach-
teile generieren. Doch ohne eine
breite industrielle Basis, auch von
energieintensiven Branchen, wird
das strukturelle Beschftigungspro-
blem hierzulande nicht zu lsen
GDA
sein. Umso wichtiger ist es, den
Exodus von Industrien zu stoppen.
Das schliet die Aluminiumindus-
trie ein.
Noch Anfang 2006 sah es so aus, als
htte das Httensterben in Deutsch-
land beschleunigte Fahrt aufgenom-
men. Die Schlieung des Hamburger
Aluminium-Werks HAW Ende 2005
und das angekndigte Aus frs El-
bewerk in Stade zum Jahresende
2006 warfen die Frage auf, wann es
schlielich die verbleibenden Ht-
tenbetriebe treffen wrde. Dass HAW
nun von der Trimet Aluminium AG in
Essen erworben wurde und die Elek-
trolysefen in den nchsten Monaten
wieder hochgefahren werden, knnte
als Indiz gewertet werden, dass sich
die standortpolitischen Rahmenbe-
dingungen in Deutschland zum Bes-
seren gewendet haben und es nun
wieder aufwrts geht mit dem Wirt-
schaftsstandort Deutschland.
16
Bei aller Euphorie kann jedoch nicht
bersehen werden, dass die Zukunft
fr energieintensive Unternehmen in
Deutschland nebelverhangen bleibt.
Generell gilt dagegen: Die Energie-
und insbesondere die Strompreise
sind im internationalen Mastab nach
wie vor sehr hoch. Auch die politisch
bedingten Energiekosten belasten
trotz regierungsseitig beschlossener
Erleichterungen weiterhin.
GDA-Geschftsfhrer Christian Wellner:
Alle Bestrebungen zur Optimierung des
Elektrolysebetriebes zielen auf ...
Planungssicherheit ber Zeitrume,
die sich in Jahrzehnten statt Jahren
bemessen, gibt es somit nach wie vor
nicht. Das belastet die Httenbetrei-
ber mit erheblichen Risiken, wenn sie
ntige Investitionen in ihre Anlagen
planen oder sie wagen es gar nicht,
was ein allmhliches Ende des Be-
triebs zur Konsequenz hat.
Und all dies vor dem Hintergrund,
dass die deutschen Aluminiumhtten
heute technologisch und mit Blick auf
die Umweltstandards international auf
Augenhhe produzieren, ja vorbild-
lich sind. All dies auch vor dem Hin-
tergrund, dass wir es in der Branche
keineswegs mit einem Verdrngungs-
wettbewerb in einem schrumpfenden
Markt zu tun haben. Im Gegenteil: Die
Produktion von Primraluminium
stieg zwischen 2000 und 2005 welt-
weit um rund 38 Prozent auf knapp
34 Mio. jato und die Nachfrage nach
Aluminium wird in den kommenden
Jahren weiter steigen.
Die Entwicklung des
Httenstandorts Deutschland
Es ist eine Ironie der Geschichte, dass
die Standortprobleme in einem Land
auftreten, das zu den ltesten Htten-
standorten fr Aluminium zhlt. Der
erste Elektrolysebetrieb in Deutsch-
land wurde schon 1898 in Rhein-
felden an der Grenze zur Schweiz
errichtet, wo dank der Rheinflle der
erforderliche Strom zur Aluminium-
produktion kostengnstig bereitge-
stellt werden konnte.
Niedrige Strompreise sind fr die
Primrhtten seit jeher unabdingbar.
Deshalb entstanden ab 1917 groe
Aluminiumwerke am Niederrhein
(Erftwerk) und in der Lausitz (Lauta-
werk), beide bezogen ihren Strom auf
Basis gnstiger Braunkohle. Mitte der
1920er Jahre wurde das Innwerk in
Tging und in den 1930er Jahren das
Lippewerk in Lnen gebaut. Anfang
der 1960er Jahre wurde das Rhein-
werk bei Neuss errichtet. Weitere
Kapazitten wurden schlielich in
Essen, Ludwigshafen, Voerde, Stade
und Hamburg geschaffen.
Die grte Anlagenkapazitt in
Deutschland gab es 1985/86 mit
790.000 jato, als insgesamt neun Alu-
miniumhtten produzierten. Heu-
te wird nur noch an wenigen der
genannten Standorte Primrmetall
erzeugt. Das Erftwerk schloss seine
Elektrolyse bereits 1978, die Alumi-
niumhtte in Ludwigshafen 1987, das
Lippewerk 1989, die Aluminiumhtte
in Rheinfelden 1991 und das Innwerk
1996. Das Elbewerk in Stade hat sei-
ne Tore vor wenigen Wochen (70.000
jato) geschlossen.
War es frher eher eine zu geringe
Betriebsgre bzw. ineffiziente Pro-
duktion, die zum Aus fr eine Htte
ALUMINIUM 1-2/2007

fhrte, haben sich seit der Jahrtau-
sendwende vor allem die erheblich ge-
stiegenen Energiekosten zum Existenz
bedrohenden Kriterium verschlim-
mert. Dies wirft die Frage auf, wie
lange die heute in Deutschland noch
produzierenden Elektrolysen betrie-
ben werden knnen. Stromvertrge
zwischen den Energieversorgern und
den Htten werden nur noch kurzfri-
stig fr einige Jahre abgeschlossen,
so dass das Damoklesschwert einer
Betriebsschlieung permanent ber
den Unternehmen und ihren Beschf-
tigten hngt obwohl, wie erwhnt,
die deutschen Anlagen hoch effizient
produzieren und technisch internati-
onal wettbewerbsfhig sind.
Elektrolyseprozess deutlich
effizienter
Das Prinzip der Aluminiumgewin-
nung ist in den vergangenen 100
Jahren zwar weitgehend unverndert
geblieben, doch wurden in den ver-
gangenen Jahrzehnten Modernisie-
rungen durchgefhrt, die die heutige
Produktion wesentlich effizienter
macht als frher. Alle Bestrebungen
zur Optimierung des Elektrolysebe-
triebes zielen auf eine hohe Stromaus-
beute, einen niedrigen spezifischen
Energieverbrauch der Zellen und ei-
nen geringen Anodenverbrauch. Auf
diese Weise konnten die Produktivitt
enorm gesteigert und schdliche Um-
weltwirkungen minimiert werden.
Die im Laufe der vergangenen
Jahrzehnte getroffenen Manahmen
dazu sind vielfltig: Alle fen in
Deutschland sind seit Jahrzehnten
komplett gekapselt und bleiben auch
whrend der Oxidzufuhr geschlossen.
Die Entdeckung, dass der spezifische
Elektrolytwiderstand mit dem Oxid-
gehalt korreliert, war zwar schon
ALUMINIUM 1-2/2007
... eine hohe Stromausbeute, einen niedrigen spezifischen Energieverbrauch der Zellen ...
lnger bekannt. Dennoch hat es erst
die Entwicklung einer Technologie
zur przisen Dosierung von Tonerde
durch Prozesskontrollrechner, die so-
genannte Point-Feeder-Methode, er-
mglicht, Anodeneffekte weitgehend
zu vermeiden.
Die Betriebsfhrung mit hohen
Stromstrken sowie durch compu-
tergesttzte Steuerungssysteme und
Dosiereinrichtungen machen die
Schmelzflusselektrolyse hoch effizi-
ent und umweltvertrglich. Der Rein-
heitsgehalt des Aluminiums liegt bei
99,7 Prozent. Die Stromausbeute be-
trgt bei den modernen Hochstrom-
Elektrolysezellen rund 95 Prozent.
Der spezifische Strombedarf liegt in
deutschen Htten um die 14 kWh/kg
Aluminium ein erheblicher Fort-
schritt gegenber 50 kWh/kg zu Be-
ginn der industriellen Aluminiumer-
zeugung um 1900 und 20 kWh/kg
in den 1970er Jahren. Mit den Pro-
zessoptimierungen der vergangenen
Jahre zeichnet sich zugleich ab, dass
das technische Potenzial zu weiteren
WIRTSCHAFT
Corus Aluminium Voerde, Fotograf Thea Weires
Verbrauchsabsenkungen weitgehend
ausgeschpft ist.
Moderne Techniken der
Luftreinhaltung
Die Manahmen zur Prozessverbes-
serung umfassten stets auch die Tech-
niken zur Luftreinhaltung. Als Emis-
sionen der Elektrolyse, die gereinigt
werden mssen, treten vor allem die
Komponenten Staub und Fluorwas-
serstoff auf. Vor wenigen Jahrzehnten
war die beste Methode der Staubab-
scheidung noch die Abtrennung mit
Zyklonen, fr die Fluoridabscheidung
war es die Abgaswsche mit Kalkmilch
und anschlieender Fllung und Ab-
trennung des gebildeten Calciumfluo-
rids. Dieser Feststoff musste abfiltriert
und deponiert werden. Allein fr die
Luftreinhaltung einer Elektrolyse von
rund 78.000 jato bedeutete dies einen
Wassereinsatz von circa 100.000 m3
pro Jahr und ein Abfallaufkommen
von rund 6.000 Tonnen Calciumflu-
oridschlamm.
17
 WIRTSCHAFT
Mitte der 1980er Jahre kam eine in-
novative Technik auf den Markt, die
mit der TA Luft 1986 schnell in die
Htten integriert wurde. Diese neue
Technik nutzt aus, dass Tonerde in
der Lage ist, gasfrmige Stoffe zu ab-
sorbieren, also an ihrer Oberflche
anzulagern. Der Staub, der durch die
Zugabe von Tonerde zur Absorption
der Fluorwasserstoffe im Rohgas ent-
steht, lsst sich mit einem Gewebefil-
ter unproblematisch abreinigen. Die
mit Fluoriden angereicherte Tonerde
wird in die Elektrolyse zurckgefhrt,
was den erforderlichen Einsatz von
Aluminiumfluorid weiter reduziert.
Insgesamt knnen die Fluoride mit
einem Wirkungsgrad von ber 99 Pro-
zent aus dem Abgas entfernt werden.
Die Vorteile dieses Verfahrens
sind offensichtlich: Der hohe Ab-
scheidegrad von Fluorid entlastet die
Umwelt, es werden wertvolle Einsatz-
stoffe zurckgewonnen, auerdem
Corus Aluminium Voerde, Fotograf Thea Weires
... und einen geringen Anodenverbrauch.
wird Wasser eingespart und das Ab-
fallaufkommen reduziert. Die damit
verbundenen Vorteile fr die Um-
welt gehen mit Kosteneinsparungen
einher eine ideale Situation, in der
sich kologische und konomische
Vorteile gleichermaen ergeben.
Anodeneffekte minimiert
Weitere umweltorientierte Manah-
men zielten darauf, den sogenann-
ten Anodeneffekt zu minimieren. Er
ist durch einen raschen Anstieg der
Spannung in den Elektrolysezellen
gekennzeichnet, die kurzfristig auf das
6-fache ansteigen kann. Dabei kommt
18
es infolge einer lokalen Verarmung
an Aluminiumoxid zu einer Zerset-
zung des Kryoliths und zur Bildung
von Tetrafluormethan (CF4) und He-
xafluorethan (C2F6). Die Ursache fr
das Entstehen eines Anodeneffektes
kann eine abnehmende Tonerdekon-
zentration im Schmelzbad oder das
berschreiten der kritischen Strom-
dichte in der Elektrolysezelle sein:
zum Beispiel verstopfte Point-Feeder,
das Wechseln der Tonerdesorte und
damit verbundene Lslichkeitspro-
bleme, ein Anodenwechsel oder das
Absaugen von Metall.
CF4 und C2F6 sind nicht toxisch und
fr Menschen und Tiere unschdlich,
gelten jedoch als Klimagase. Sie ent-
stehen nur kurzfristig whrend des
Anodeneffektes und treten in relativ
geringen Mengen auf.
Die deutschen Primrhtten ha-
ben seit 1990 eine Menge getan, um
den Anodeneffekt und das Entste-
hen dieser Gase zu unterbinden. So
wurden 2005 in den damals produ-
zierenden fnf deutschen Htten
insgesamt 270 Tonnen weniger CF4
emittiert als 1990. Die spezifischen
Emissionen lagen durchschnittlich
bei knapp 0,07 kg/t Aluminium. Die
gegenber der Bundesregierung abge-
gebene Selbstverpflichtung der deut-
schen Primraluminiumhtten, die
CF4/C2F6-Emissionen zwischen 1990
und 2005 absolut und auch spezifisch
um die Hlfte zu vermindern, wurde
damit deutlich bererfllt.
Die deutschen Aluminiumhtten
bewegen sich im weltweiten Vergleich
bei den CF4-Emissionen in einem ab-
soluten Spitzenfeld. Sie liegen mit
den erwhnten 0,07 kg/t auch um fast
zwei Drittel unter dem vom Internati-
onal Aluminium Institute (IAI) fr das
Jahr 2000 ermittelten internationalen
Referenzwert von 0,22 kg/t CF4. Sogar
der IAI-Durchschnittswert speziell
fr Point-Feeder-Anlagen von 0,11
kg/t wird von den deutschen Anlagen
klar unterschritten. Bei diesem stati-
stischen Vergleich ist wichtig anzu-
merken, dass technisch rckstndige
chinesischen und russischen Anlagen
in den IAI-Zahlen nicht einbezogen
sind. Inzwischen ist das Modernisie-
rungspotenzial durch eine weiter ver-
besserte Ofensteuerung hierzulande
technisch weitgehend ausgereizt. Da
der Treibhauseffekt eine globale He-
rausforderung ist, kommt es knftig
verstrkt darauf an, dass die groen
Aluminiumproduzenten Russland
und China ihre veraltete Anlagentech-
nik modernisieren. Mit Manahmen,
wie sie in den vergangenen Jahren in
Deutschland umgesetzt wurden, liee
sich ein enormes Potenzial zur Emis-
sionsminderung erschlieen.
Energie- und standortpolitische
Sonderlasten
Die Errichtung neuer Htten erfolgt
heute auerhalb Europas an Standor-
ten, die ber preiswerte Energie ver-
fgen, wie dies zum Beispiel in Katar
der Fall ist. Dort wird bis 2009 eine
Aluminiumhtte mit einer Anfangs-
kapazitt von 570.000 Jahrestonnen
errichtet, die ber ein eigenes Kraft-
werk verfgen wird.
Dies ist keine Perspektive hier-
zulande, doch sind Politik und Ge-
sellschaft gefordert, die industriellen
Rahmenbedingungen der deutschen
Volkswirtschaft so zu verbessern,
dass die schleichende Deindustri-
alisierung gestoppt wird und Wirt-
schaftswachstum und Beschftigung
deutlich gestrkt werden. Daher
ist es unverzichtbar, jede Stufe der
Wertschpfungskette durch eine
Wirtschaftspolitik zu halten, die den
Standort Deutschland strkt und den
fairen Wettbewerb mit dem Ausland
ermglicht.
Die deutsche Energiepolitik muss
dazu ebenfalls einen Beitrag leisten,
orientiert sich aber seit Jahren fast
ALUMINIUM 1-2/2007

ausschlielich an Klimazielen. Statt
sich auf die wahren Herausforde-
rungen zu konzentrieren, die sich aus
der langfristigen Entwicklung auf den
internationalen Energiemrkten er-
geben, leistet sich die deutsche Ener-
giepolitik den Ausstieg aus der Kern-
energie ohne klares Bekenntnis zur
Steinkohle als Ersatzenergie, gepaart
mit einer massiven Subventionierung
der erneuerbaren Energien durch im-
mer hhere koabgaben und ergnzt
um eine CO2-Zertifikatepolitik, die
den Stromkonzernen riesige Windfall
Profits einbringt, die von Haushalts-
und Industriekunden gleichermaen
finanziert werden.
Rechnet man die CF4-Reduktion
(2005: 270 t) um, die die Aluminium-
htten durch erhebliche Investitionen
an CO2-Menge eingespart haben, er-
gibt dies gemessen an den aktuellen
Marktpreisen fr Emissionszertifikate
eine Sonderleistung im Wert von
mehreren Millionen Euro, mit denen
die deutschen Aluminiumhtten zum
deutschen Klimaschutz fr die Welt
beigetragen haben.
Wertschpfungsglieder eng
verzahnt
Die kostenlose Zuweisung von Emis-
sionszertifikaten nach dem Natio-
nalen Allokationsplan II wird die
Strompreise weiter in die Hhe trei-
ben, obwohl der bergroe Teil des
produzierten Stroms vom Zertifikate-
preis gar nicht beeinflusst wird. Fr
eine Aluminiumhtte, in der ber ein
Drittel der Produktionskosten vom
Strompreis diktiert wird, ist eine sol-
che Entwicklung katastrophal. Doch
auch die weiterverarbeitenden Alu-
miniumbetriebe sind auf kostengn-
stige Energie angewiesen und mssen
frchten, dass ihr Innovationsvorteil
gegenber wachsender globaler Kon-
kurrenz durch weiter steigende Mehr-
kosten aufgefressen wird, bis auch sie
nicht mehr im Wettbewerb bestehen
knnen.
Wer heute meint, die energieinten-
sive Grundstoffindustrie sei verzicht-
bar, muss sich morgen nicht wundern,
wenn die verarbeitenden Betriebe in
dieser Wertschpfungskette in den
Sog der Produktionsverlagerung gera-
ten. Und bermorgen die Forschungs-
ALUMINIUM 1-2/2007
WIRTSCHAFT
und Entwicklungszentren der Unter- den Werkstoff an seine Zugfestig-
nehmen folgen, was am Ende negative keit, an sein Umformvermgen, an
Rckwirkungen bis hin zum Dienst- seine Gefgeeigenschaften , die
leistungssektor htte. oft in jahrzehntelang gewachsenen
Die Aluminiumindustrie ist durch Kunden-Lieferanten-Beziehungen
eine enge Verzahnung der einzelnen zwischen Aluminiumproduzent und
Glieder in der Wertschpfungskette Verarbeiter gelst worden sind. Diese
Metallerzeugung, Halbzeugfertigung, Technologiepartnerschaft zwischen
Endprodukt geprgt. Dabei zeigt sich, den Wertschpfungsgliedern ist viel-
dass optimale Produktlsungen sich fach fr die hohe Produktqualitt und
gerade dann erzielen lassen, wenn den viel beschworenen Exporterfolg,
zwischen den einzelnen Wertschp- auch von Unternehmen der Alumini-
fungsgliedern eine enge Zusammen- umbranche, mitverantwortlich.
arbeit besteht, in der das gesamte In einer solchen Technologie-
Know-how und die Erfahrung aller partnerschaft kommt den Htten als
Beteiligten zum Tragen kommen: Basis des Geschfts eine wichtige
von der Werkstoff-, Fertigungs- und konomische Funktion zu. In einer
Entwicklungskompetenz bis hin zur globalisierten Welt, in der sogar mit-
Qualittssicherung, Logistik und dem telstndische Unternehmen Produk-
Service. tionsstandorte in Osteuropa, Asien
In diesem Kompetenzverbund und Lateinamerika errichten, ist die
knnte die rumliche Nhe zwischen Gefahr eines Domino-Effektes Erst
den einzelnen Fertigungsstufen, kur- gehen die Htten, dann die Verar-
ze Kommunikations- und Logistik- beitung konkreter denn je. Wenn
wege zwischen Kunde und Lieferant logistische Vorteile, etwa durch die
im internationalen Wettbewerb ein Versorgungsnhe zu den Htten-
Standortvorteil sein, wenn die wirt- produzenten, wegfallen und sich die
schaftlichen Rahmenbedingungen ei- Waage dadurch weiter zuungunsten
nen fairen Wettbewerb mit dem Aus- des Standorts Deutschland neigt, wer-
land zulieen. Aluminium ist eben den die Verarbeitungsbetriebe ihre
lngst kein 08/15-Produkt mehr. Viele Kosten-Nutzen-Rechnung neu auf-
Walz- und Strangpresswerke, Form- stellen.
gieereien und weitere Verarbeiter
bentigen fr ihre hochwertigen Autoren
Produkte Aluminiumlegierungen
mit definierten Qualitten. Eine Christian Wellner ist Geschftsfhrer des
Lithoplatte fr den Offsetdruck, ein Gesamtverbandes der Aluminiumindus-
trie (GDA), Dsseldorf.
Fahrwerksteil fr Pkw, ein Auen- Jrg H. Schfer ist Referent fr Nach-
hautblech fr Flugzeuge und zahl- haltigkeit beim GDA und leitet dort den
reiche andere Produkte stellen je- Fachbereich Metallpulver.
weils spezifische Anforderungen an
World leader in
molten metal level control
PreciMeter Control AB, Sweden
phone +46 31 764 55 20 fax +46 31 764 55 29
sales@precimeter.se www.precimeter.com
19
WIRTSCHAFT
Herbstkongress der European Coil Coating Association
Marktentwicklung, Technologie-
trends, Gesetzgebung
Unter dem Motto Reviewing the
advantages of coil coating against
competitive materials bot die
ECCA auf ihrem Herbst-Kongress
in Brssel Ende 2006 einen ber-
blick ber die Marktentwicklung,
ber neue Technologien bei der
Bandbeschichtung von Aluminium
und Stahl sowie ber die Weiter-
verarbeitung und Anwendung vor-
lackierter Bnder.
Die Ablieferungen an beschichteten
Aluminium- und Stahlbndern durch
die ECCA-Mitglieder hatten 2004
mit einer Gesamtmenge von ber 1,4
Mio. m2 den bisherigen Hchststand
erreicht.
Marktentwicklung
Nachdem das Jahr 2005 leicht rck-
lufig war, kann fr das erste Halb-
jahr 2006 von einer Erholung auf
dem Niveau von 2004 ausgegangen
werden. Vergleichbare Zahlen aus der
European Coil Coating Association
Die ECCA existiert seit 1967 als Verei-
nigung der europischen Coil Coating
Industrie. Die derzeit rund 200 Mitglieds-
firmen sind vor allem europische, teils
aber auch auereuropische Bandher-
steller und -veredler sowie Lackhersteller,
Anlagenbauer, Zulieferer und Handelsun-
ternehmen. Ziel der ECCA ist es, die Ver-
wendung von vorlackierten Bndern und
Blechen aus Aluminium und Stahl als
umweltvertrgliche, kosteneffiziente und
qualitativ wertvolle Methode zur Erzeu-
gung von Fertigerzeugnissen zu frdern.
Dabei widmet sich der Verband neben
dem politischen Lobbying der Entwick-
lung von Qualittsstandards (verbunden
mit der Entwicklung von Testmethoden).
Darber hinaus fhrt er Trainingskurse
durch, um die Verwendung vorlackierter
Metalle bei Designern und Herstellern
bekannt zu machen.
20
nordamerikanischen und asiatischen
Region liegen noch nicht vor. In Nord-
amerika ist jedoch davon auszugehen,
dass der rcklufige Trend weiter an-
hlt. Ganz anders die Entwicklung in
Asien, allen voran China und Indien.
Dort sind neue Coil-Coating-Linien in
Betrieb gegangen, die diesen Lndern
nicht nur eine partielle Unabhngig-
keit von Importen ermglichen. Beide
Lnder haben zudem bewiesen, dass
sie, wenngleich noch mit geringen
Mengen, durchaus zu Exporten in
europische Regionen wie Italien und
Spanien fhig sind.
Hauptanwender von Produkten
aus organisch beschichteten Alumini-
um- und Stahlblechen und -bndern
bleibt das Bauwesen mit zahlreichen
Anwendungen im Auen- und Innen-
bau. Bei beschichteten Aluminium-
bndern waren das rund 70 Prozent,
bei Stahlbndern 67 Prozent der 2005
erzeugten 224 Mio. bzw. 1.141 Mio.
m2.
Die auf dem Kongress gezeigten
Beispiele sthetisch gelungener An-
wendungen bei ffentlichen und B-
rogebuden, aber auch zunehmend
im privaten Hausbau spiegelten die
unzhligen Variationsmglichkeiten
aus Form und Farbe wider. Im Seg-
ment Fassadentechnik wird weiteres
Marktwachstum innerhalb bautech-
nischer Anwendungen erwartet. Dies
gilt sowohl fr Neubauten als auch fr
die Sanierung vorhandener Bausub-
stanz. Hierbei sollen Profilelemente
und Sandwichplatten zunehmend
konventionelle Werkstoffe wie Beton,
Backstein, Holz und Glas ersetzen.
Gepunktet wird dabei mit den lang-
fristigen Kostenvorteilen dank War-
tungsfreiheit und mit Kriterien wie
Umweltvertrglichkeit, Brandschutz
und modernes Design bandbeschich-
teter Substrate. Ein weiterer Trend ist,
dass immer mehr Architekten neben
Form und Funktion die Wirkung der
Farbe entdecken.
Weitere wichtige Einsatzgebiete fr
bandbeschichtetes Aluminium und
Autumn congress of the ECCA
Market development,
technology trends,
legislation
Under the heading Reviewing the
advantages of coil coating against
competitive materials, at its au-
tumn congress in Brussels at the
end of 2006 the ECCA presented
a review of market developments,
new technologies for the coil coa-
ting of aluminium and steel, and
the further processing and uses of
pre-painted strip.
In 2004 deliveries of coated alumini-
um and steel strips by ECCA members
amounted to 1.4 million m2, more that
ever before.
Market development
Following a slight downturn in 2005,
it is expected that there was a recov-
ery in the first half-year of 2006 to
the level of 2004. Comparable figures
from the North American and Asiatic
regions are not yet available, but it can
be assumed that in North America the
recessionary trend is still persisting.
The development in Asia is quite the
opposite, most of all in China and In-
dia where new coil-coating lines have
come into operation, which have made
those countries more than partially in-
dependent of imports. Both countries
have indicated that, although still in
small quantities, they are fully capable
of exporting to European countries
such as Italy and Spain.
The largest user of products made
from organically coated aluminium
and steel sheets and strips is still the
building industry, with numerous out-
door and indoor applications. In the
case of coated aluminium strips these
accounted for some 70 per cent, and
in the case of steel strips 67 per cent
of the respective total productions of
224 million and 1,141 million m2 in
2005.
The examples exhibited at the
congress, showing aesthetically suc-
cessful applications in public and
office buildings but to an increasing
extent also in the building of private
ALUMINIUM 1-2/2007
 ECONOMICS

residences, reflected the countless
possible variations of shape and col-
our. In the sector of faade technology
further market growth in the field of
building applications is anticipated.
This applies both to new buildings
and in the refurbishment of exist-
ing structures. Section elements and
sandwich plates will increasingly re-
place conventional materials such
as concrete, brick, wood and glass.
This is encouraged by long-term cost
benefits thanks to low maintenance
requirements, and by criteria such as
environment-friendliness, fire protec-
tion and the modern designs that can
be produced from strip-coated sub-
strates. A further trend is that more
and more architects are discovering
the effects of colour in addition to
shape and functionality.
Other important fields of use for
strip-coated aluminium and steel,
which come next although with re-
Stahl, die mit Anteilen von unter zehn
Prozent folgen, sind der Fahrzeugbau
und die Hausgerteindustrie. Wh-
rend bei Hausgerten fertig lackierte
Bnder seit Jahren als Stand der Tech-
nik verwendet werden, beschrnken
sich die Automobilhersteller nach wie
vor auf den Einsatz funktionsbeschich-
teter Bleche. Hier spielen chemische
Behandlungen zur Verbesserung der
Haftvermittlung und Schmierstoffe
fr die Umformung eine Rolle. Der
Einsatz von fertig lackiertem Stahl
oder Aluminium in der Karosserie
scheitert bislang noch an vielerlei
Problemen: zum Beispiel am Korrosi-
onsschutz der Schnittkanten oder an
einer lackvertrglichen, automobil-
gerechten Fgetechnik. Dies hat zur
Folge, dass Autos auch in Zukunft
ihre Endlackierung erst an der zu-
sammengebauten Karosserie erhalten
werden.

spective shares of less than 10%, are
vehicle engineering and the house-
hold appliances industry. Whereas
finish-painted strips have been used
as standard for years in the appliances
industry, automobile engineers still
restrict themselves to the use of sheets
with functional coatings, including
chemical treatments to improve ad-
hesion and lubricants for deformation
processes. The use of finish-painted
steel or aluminium for auto bodies is
still held back by many problems, for
example the cut edge corrosion pro-
tection or joining methods compatible
with the paint and which are suitable
for use in automobiles. As a result,
in the future too automobiles will be
given their final paint treatment only
after assembly of the body shell.
Technology trends
Technological development, both for
coating and for the further processing
of coated strips and sheets, is con-
tinually being taken further by both
manufacturers and users. The core
theme of a series of presentations
was the development of new coating
products. Improved property profiles
of products and processes are orien-
tated towards economy, environment
protection, technology and aesthetics.
Fata Hunter
Technologie-Trends
Die technologische Entwicklung so-
wohl bei der Beschichtung als auch
bei der Weiterverarbeitung beschich-
teter Bnder und Bleche wird von
Herstellern und Anwendern stetig
vorangetrieben. Kernthemen der Vor-
tragsreihe galten der Entwicklung
neuer Produkte fr die Beschichtung.
Verbesserte Eigenschaftsprofile von
Produkten und Prozessen sind auf
Wirtschaftlichkeit, Umweltschutz,
Technologie und sthetik ausgerich-
tet. Seitens der Beschichter gehen die
Forderungen in Richtung Automati-
sierung, Einfhrung schnellerer Ver-
fahren und verbesserte Prozessstabi-
litt. Die Entwicklung neuer Lacke fr
bautechnische Anwendungen, die zur
Abstrahlung der Sonnenenergie kon-
zipiert sind, zielen darauf, den Ener-
gieverbrauch zur Gebudekhlung
deutlich zu reduzieren. Fr die Ent-
wicklung solcher Lacke wird von den
Herstellern eine spezielle Software
eingesetzt, welche die Umgebungs-
einflsse unterschiedlicher Orte si-
muliert. Nach wie vor bleiben chrom-
freie Vorbehandlungen und Lacke ein
Schwerpunkt der Entwicklung. Die
mittlerweile verfgbaren Produkte
entsprechen hinsichtlich Korrosions-
bestndigkeit und Lackhaftung den
Fata Hunter: Eine von zwei nach China
gelieferten Bandbeschichtungslinien
Fata Hunter: One of two parallel coil
coating lines supplied to China
Eigenschaften bisher verwendeter
chrombasierter Erzeugnisse.
Weitere Entwicklungsziele gelten
dem Korrosionsschutz der Schnitt-
kanten ohne Primereinsatz. Der Ein-
satz von Antikorrosionslacken auf
unbeschichtete Substrate wird noch
einige Jahre auf sich warten lassen.
Die Adphos AG berichtete ber
ihre Weiterentwicklungen bei der
NIR-Aushrtung von organischen
Beschichtungen. NIR steht fr Near
Infra Red und beschreibt ein Verfah-
ren, mit dem im nahen Infrarotbereich
mittels speziellen Hochleistungsstrah-
lern, die eine Energiedichte von bis zu
3.000 kW pro Quadratmeter besitzen,
eine sehr schnelle direkte Aufheizung
der organischen Beschichtung er-
reicht wird. Die Folge sind sehr kurze
Prozesszeiten in der Grenordnung
von ein bis drei Sekunden, verglichen
mit den 15 bis 25 Sekunden bei kon-
ventionellen fen. Dank der unmit-
telbaren Trocknung und Aushrtung
durch NIR wird ein sehr schneller
und nahezu schrottendenfreier Farb-

ALUMINIUM 1-2/2007 21
 WIRTSCHAFT
Siemens VAI
Siemens VAI: Eingangsbereich einer Bandbeschichtungsanlage in Polen
Siemens VAI: Entry section of a coil coating line in Poland
wechsel bei Coil-Coating-Linien,
aber auch bei kombinierten Verzin-
kungs- und Beschichtungslinien er-
reicht. Die NIR-Technik ermglicht
eine wirtschaftliche und flexible Ver-
arbeitung auch kleinster Losgren
und kommt damit dem kundenorien-
tierten Trend zu immer enger gestuf-
ten Farbnuancen entgegen. Bei der
Modernisierung vorhandener Anla-
gen gestattet die kurze Bauweise der
NIR-Trockner den Einbau weiterer
Coater fr einen mehrschichtigen
Lackauftrag in einem Banddurchlauf.
Bauteile aus fertig lackierten Bn-
dern und Blechen werden durch un-
terschiedliche mechanische Bearbei-
tungsvorgnge wie Stanzen, Biegen,
Tiefziehen oder Walzprofilieren in
ihre endgltige Form gebracht. Viele
dieser Bearbeitungen erfordern vom
Beschichter das Aufbringen von Fo-
lien zum Schutz der lackierten Ober-
flchen whrend der Bearbeitung.
Die hollndische Firma Wemo stellte
ringen Radien abkanten. Neben dem fr den Umgang mit Gefahrenstoffen
Umformen widmet sich das Unter- werden zur Substitution von Stoffen
nehmen auch Methoden zum Fgen fhren. Dies wird die unternehme-
bandbeschichteter Bleche: je nach rische Ttigkeit stark berhren. Die
Blechdicke und Verwendungszweck Empfehlung an die Unternehmen
durch Widerstands-Buckelschweien lautet, frhzeitig einen vorausschau-
oder punktuelles Durchsetzfgen. enden Ansatz fr organisatorische
Anpassungen zu verfolgen, um so den
Gesetzgebung Ersatz von Substanzen und mgliche
nderungen der gesamten Prozess-
Mehr Forderungen als derzeit bekann- kette mglichst reibungslos zu bewir-
te konkrete Umsetzungen enthielt ken zumal die Umsetzungsphase
die Information ber die europische relativ kurz ist.
REACH-Verordnung (Registration, B. Rieth
Evaluation, Authorization of Chemi-
cals). Klar ist, dass auf die Hersteller,
Importeure und Anwender von che-
mischen Substanzen und damit auf
die gesamte mit dem Coil Coating be-
fasste Industrie neue Verordnungen
zukommen. Derzeit am konkretesten
ist der Zeitplan fr die stufenweise
Einfhrung: Auf erste Schritte zur
Einfhrung ab April 2007 folgt von
April 2008 bis April 2010 eine Erfas-
 


Werkzeuge vor, mit denen auch unge- sungsperiode. Weitere Meilensteine 


 



schtzte Lackflchen ohne Beschdi- im Hinblick auf die mengenmige
#"%&"&"%&$*

gung bearbeitet werden knnen. Die Relevanz sind der April 2010 und der 

+"" 
so genannte swivel bending techno- April 2013 bis zur vollen Wirksam-
 #"  


   
logy verwendet gelenkig bettigte werdung ab April 2018.  (  


   

Balken, die mit einer Relativbewe- Was bedeutet das fr Produzenten ! "#"#&$!!
"&$"& '''"#&$!!
gung und damit kratzerfrei mit ge- und Anwender? Neue Vorschriften

22 ALUMINIUM 1-2/2007

From the coaters standpoint what is
needed is more automation, the in-
troduction of more rapid processes,
and improved process stability. The
development of new paints for build-
ing applications, which are designed
to reflect back solar energy, aim to
reduce considerably the energy con-
sumed for the cooling of buildings.
For the development of such paints
manufacturers use special software
which simulates the influence of the
surroundings at a variety of locations.
As before, chromium-free pretreat-
ments and paints are at the focus of
development. The products that have
meanwhile become available match
the properties of the previously used,
chromium-based products in relation
to corrosion resistance and paint ad-
hesion.
A further development objective is
cut edge corrosion protection without
the use of a primer. The use of anti-
corrosion paints on uncoated sub-
strates is still a few years off. Adphos
AG reported its further developments
in the NIR hardening of organic coat-
ings. NIR stands for Near Infra Red
and describes a process in which high-
powered radiators operating with an
energy density of up to 3,000 kW/m2
in the near infra-red range are used
for the very rapid direct heating of the
organic coating. This results in very
short process times of the order of 1
to 3 seconds, instead of the 15 to 25
second in conventional ovens. Thanks
to the direct drying and hardening by
NIR very rapid colour modification al-
most without scrap offcuts is achieved
on coil-coating lines, but also on com-
bined galvanising and coating lines.
The NIR technique enables economi-
cal and flexible processing even of
very small batch sizes, and is there-
ALUMINIUM 1-2/2007
fore well suited to satisfy the increas-
ing demand by customers for ever
more subtle colour nuances. When
existing plants are being modernised,
the compact structure of NIR driers
enables further coaters to be fitted in
for multi-layer paint application dur-
ing a single pass of the strip.
Articles made of finish-painted
strips and sheets are given their fi-
nal shape by a variety of mechanical
processes such as stamping, bending,
deep-drawing or roll-profiling. Many
of these methods require the coater to
apply foils in order to protect the pain
surface during processing. The Dutch
company Wemo described tools with
which even unprotected painted sur-
faces can be worked without dam-
age. The so-termed swivel bending
technology uses articulated beams
that can bend through tight radii with
a relative movement and therefore
without scratching. Besides shaping
methods, the company also focuses
on methods for joining strip-coated
sheets: depending on the sheet thick-
ness and the intended use, by resist-
ance stud welding or point to point
penetration welding.
Legislation
The report concerning the European
REACH (Registration, Evaluation and
Authorisation of Chemicals) Direc-
tive gave notice of more requirements
than there are at present known and
concrete conversion provisions. What
is clear, is that there are new direc-
tives to come, which will affect the
manufacturers, importers and users of
chemical substances and therefore the
entire range of industry that has to do
with coil coating. The most concrete
aspect at present is the timetable for
ECONOMICS
European Coil Coating Association
The ECCA has existed since 1967 as the
Association for the European coil coating
industry. Its 200 members are mainly Eu-
ropean companies but also include from
outside Europe a number of strip produ-
cers and finishers as well as paint manuf-
acturers, plant engineering companies,
suppliers and trading companies. ECCA is
to promote the use of pre-painted strips
and sheets of aluminium and steel, as
environmentally safe, cost-effective and
qualitatively high-grade means for the
production of finished goods. For this,
the ECCA engages in political lobbying
and in the development of quality
standards (combined with the develop-
ment of test methods). Furthermore, it
organises training courses to familiarise
designers and manufacturers with the
uses of pre-painted metals.
gradual implementation: after the first
introduction step from April 2007 on-
ward, between April 2008 and April
2010 there will be a period of adapta-
tion. Other milestones of quantitative
relevance are April 2010 and April
2013, until the Directive comes fully
into effect from April 2018.
What does this mean for produc-
ers and users? New prescriptions for
operating with hazardous substances
will lead to substance substitutions.
This will greatly affect company ac-
tivities. The recommendation for
companies is to be prompt in plan-
ning anticipatory action for organisa-
tional adaptations, so as to implement
substance replacements and possible
modifications of the entire process
chain with as few problems as pos-
sible especially since the conversion
phase is relatively short. B. Rieth
23
ECONOMICS
The Russians are coming: example Rusal
R. P. Pawlek, Sierre
Russian companies have hit the
headlines recently, surprising the
established business world with
their sudden emergence as major
global players. From steelmaker
Severstal, to aluminium producer
Rusal and energy giants Lukoil
and Gazprom, these emerging
Russian multinationals are buil-
ding on successful acquisition
sprees, at home and abroad, to
stake a claim for global market
leadership.
Western companies need to take a
fresh look at these rapidly changing,
emerging multinationals and recog-
nise that they are primarily driven
by commercial logic and competi-
tive advantage. Equally, the emerging
Russian giants need to focus on im-
proving their image by systematically
institutionalising international best
practice standards in key areas such
as transparency, corporate govern-
ance, accounting and environmental
standards.
The emergence of new multina-
tionals in Russia is part of a broader
global phenomenon. Indeed, Russia is
now the third biggest foreign inves-
tor among emerging markets. Emerg-
ing Russian multinationals span the
entire spectrum from state-owned
giant to privately owned conglomer-
ates holding former state assets and
to newly established companies with
international shareholders.
Russian global corporate expan-
sion is still largely limited to a handful
of companies in the oil and gas, metals
and mining, and telecommunications
sectors. Most Russian multinationals
still have a regional bias, but are now
looking to invest more heavily in the
mature markets of Europe, the US and
Australia. The expansion drive began
in the CIS and Eastern Europe, and is
now moving rapidly into Africa.
Russian investors have generally
been welcomed in the CIS and Africa,
while facing a strong degree of suspi-
cion in most parts of Eastern Europe
and in the developed world. The rapid
24
pick-up in Russian investment abroad
is driven by a wide range of factors:
gaining critical mass to survive con-
solidation; getting access to new
markets, raw materials, technology
transfer and management know-how;
coping with excess liquidity and lack
of expansion opportunities at home.
Globalising Russian companies
enjoy a number of significant com-
petitive advantages over established
global players. In particular they have
emerging markets know-how as well
as a powerful but flexible corporate
structure, together with liquidity and
enormous ambition. But many Rus-
sian companies also have a number
of substantial weaknesses, including
complicated ownership structures,
a lack of transparency in corporate
culture, shallow management capaci-
ties and a poor understanding of mod-
ern environmental, health and safety
standards.
Governance weaknesses, in par-
ticular, have sullied the international
image of Russian companies, adding
to an already murky reputational leg-
acy from the 1990s and remnants of
post-Soviet cold war prejudice. Tack-
ling these weaknesses must become
a priority task for Russias emerging
multinationals.
Russias largest aluminium pro-
ducer Rusal has assets in 13 countries
in the CIS, Eastern Europe, Africa,
Latin America and Australia and has
raised US$ 2 billion in a syndicated
loan in 2006 to finance further invest-
ments. Following the current merger
with its Russian rival Sual and Swiss
commodities group Glencore, due to
be finalised by April 2007, the new
Rusal will be self-sufficient in raw ma-
terials. Its aim: to become the worlds
largest diversified energy and metals
corporation.
Russia is rapidly becoming one of
the leading foreign investors among
emerging countries although they
tend to keep a low profile about this.
First, most Russian companies are
privately owned and disclose little
information. Secondly, a high pro-
portion of investment is carried out
indirectly through offshore vehicles
and registered in host countries as
investment from Cyprus, the British
Virgin Islands and Luxembourg.
Until recently, the bulk of Russias
outward foreign investment went to
the CIS. As a result, Russian com-
panies now by far dominate foreign
investment in these difficult markets.
Rusal, for example, resuscitated Ar-
menias massive aluminium company,
now known as Armenal, which had
been forced to stop production follow-
ing the collapse of the Soviet Union.
Rusal invested over US$ 100 million
to modernize the plant, guaranteeing
a supply of raw materials, and intro-
ducing new standards of labour.
If the CIS is the near-abroad for
Russian companies, Central and
South-Eastern Europe are also famil-
iar territory, but one with a far more
ambivalent attitude towards Russian
investors. Russias leading metal com-
panies, like Evraz, Rusal and Sevestal,
are far less politicised than Gazprom,
but they are products of the oligarch
era, when well-connected entrepre-
neurs were able to buy up state assets
cheaply and then consolidate them to
forge huge corporate empires. While
these owners still play a key role in
strategic direction, the businesses they
own are changing rapidly, absorbing
international business practices as
they expand and acquire listing on
international exchanges. If Russian
investors frequently face suspicion in
ALUMINIUM 1-2/2007

Europe, they are welcomed with open
arms in Africa. Aluminium producer
Rusal, for example, is constantly look-
ing for opportunities to strengthen its
raw material base, aiming to become
self-sufficient by 2013. One of its first
moves was to move into Guinea, tak-
ing over the management of the Com-
pagnie des Bauxites de Kindia (CBK)
for a 25-year period. Guinea holds
two-thirds of the worlds bauxite re-
serves and the company was already
a traditional supplier of bauxite to the
Nikolaev Alumina Refinery in Ukraine,
which Rusal bought in 2000.
With a long history of economic
ties between Russia and Guinea, Rusal
soon expanded its operations there,
taking over the management of the
Alumina Company of Guinea, one of
the largest employers in the country,
which it is buying as the company is
privatised. Rusal has a good reputation
for doing more than just extracting re-
sources. Rusal is now implementing
a US$ 300 milion modernisation pro-
gramme to double the alumina com-
panys refining capacity over the next
three years and to improve the trans-
port, water and energy infrastructure
for both the refinery and the town.
With the Guinean authorities looking
for value-added processing to remain
in-country, Rusal is also considering
the construction of a new bauxite
and alumina complex, including an
aluminium smelter.
When Rusal bought into Austral-
ias Queensland Alumina from the
financially distressed Houston-based
Kaiser Group, its value to the Austral-
ian company was three-fold: Rusal
was a major customer for alumina,
Rusal
Primary aluminium production at Rusal
ALUMINIUM 1-2/2007
it brought new competition into the
alumina market and it wiped out Kai-
sers US$ 60 million debt, in addition
to paying US$ 401 million for a 20%
stake. With Australia holding up to
30% of global alumina production and
bauxite reserves, Rusal is now in talks
with the government to develop pow-
er-generating capacities and to build a
new aluminium smelter in the coun-
try. Rusals investment had to obtain
approval from the countrys Foreign
Investment Review Board as well as
from two existing shareholders, rival
aluminium giants Alcan and Comalco.
It took 18 months to finalise the deal
after Rusals bid won in 2004.
The rapid rise in Russias outward
investment is driven in part by global
consolidation pressures, which are es-
pecially strong in the natural resource
industries and the telecommunica-
tion sector. The globalisation process
can only be understood in the context
of Russias unique path of transition.
During the Soviet era, Russias huge
state-owned enterprises acted much
like vertically integrated multination-
als, enjoying almost complete control
of the supply chain across the net-
work of satellite states. This structure
was pulled apart by the disintegration
of the Comecon trade agreement and
the Soviet Union. As a result, one of
the major challenges facing Russian
companies ever since transition be-
gan has been how to restore the value
chain and how to find new markets to
utilise their vast excess capacity.
The energy companies quickly
moved abroad to restore their mar-
kets and improve their pricing power,
taking control of distribution channels
ECONOMICS
across the CIS and Eastern Europe.
The metals industry focused initially
more on consolidation at home, buy-
ing up assets to re-create a vertically
integrated supply chain, from raw
materials to processing and distribu-
tion. Global acquisitions are now part
of a complex strategy of securing raw
materials, expanding capacities and
opening access to new customers.
Russian companies are now looking
for long-term competitive advantage
and better margins. By buying estab-
lished companies, they get not only
technological patents, but also mar-
ket access for specialised high value-
added products.
Most of Russias leading compa-
nies have a strategy for joining the
worlds leading players in their sec-
tor. They are steadily putting the
pieces in place to make it possible
expanding capacity, opening up
markets, distributing networks and
access to raw materials. They are
not seen as world-class competitors
yet. Nevertheless, Russian companies
possess three characteristics that give
them a significant advantage over es-
tablished players. Emerging markets
know-how; liquidity; and strong, but
flexible structures.
As Russian multinationals shift
their global expansion plans up a
gear and start taking their interna-
tional competitors head on, their big-
gest obstacle will be image. Russian
companies cannot yet take over large
foreign companies, because the com-
petition for these assets is intense and
public companies still have a negative
image of Russian businesses.
In an Economist Intelligence Unit
survey more than 300 international
business executives around the world
were interviewed to explore these
perceptions. Three key findings came
out of the survey:
O Overall international business per-
ceptions of Russia are negative as a
market, an investment location and as
a source of investment.
O The level of international business
knowledge about Russia and Russian
companies is very low.
O International executives with ex-
perience in the Central and East Eu-
ropean region and knowledge of Rus-
25
ECONOMICS
sian companies have more nuanced
views but not always more positive
ones.
For Russian companies, the sur-
veys message is clear. The process
has already begun, prompted by the
need to secure international financ-
ing and work to with international
partners. Several Russian compa-
nies have now set up new corporate
governance structures. Rusal has de-
veloped an 18-month corporate gov-
ernance programme with the help of
EBRD and IFC and has appointed an
independent board, among a series of
other measures. It has also started the
Hydro maintains speed in aluminium repositioning
Hydro is well-positioned for
long-term profitable growth in its
upstream aluminium operations,
the Norwegian-based company
said at its Capital Markets Day.
Following the recommended mer-
ger of Hydros oil and gas activi-
ties with Statoil Hydro will conti-
nue as one of the worlds leading,
integrated aluminium companies.
The ongoing restructuring of the
downstream aluminium portfolio
is expected to be completed in
2007.
Hydro is stronger than ever. Our
technology, competence and finan-
cial strength, together with a broader
portfolio of development and explo-
ration projects beyond 2010, give me
great confidence in our strategy for
future growth, said Eivind Reiten,
Hydros President and Chief Execu-
tive Officer. We are manoeuvring
in an increasingly challenging global
landscape but our talented organisa-
tion, proven project execution skills
and our experience in cooperating
with partners are more valuable than
ever.
Hydros Capital Markets Day pres-
entation as to the aluminium business
included the following highlights:
Primary aluminium production is
expected to be 1.7 million tonnes in
2007 and 2 million tonnes in 2010.
26
process of disclosing information on
its ownership structure as well as data
on consolidated accounts.
The progress from the pioneer-
ing days of the 1990s is substantial
and has continued over the past few
years as companies learn from busi-
ness partners and list on international
exchanges. However, if Russian com-
panies are to become global players,
it is not enough to talk of a rhetoric
change companies will now have to
show that they run their business in
line with international norms.
As this happens, the international
business community will be forced to
Divestment of Hydros 49 per cent
share in Meridian Technologies for
73.7 million euros and divestment of
Automotive Castings for 454.3 mil-
lion euros are key steps to reduce the
engagement in the downstream alu-
minium business. Investments and
exploration expenditures in 2007 are
expected to be 491.1 million euros in
Aluminium Metal.
Aluminium Metal on track
to reposition and grow
Demand for primary aluminium is
expected to increase by 15 million
tonnes, or about 4 per cent annually,
by 2020. Rising costs is an industry
challenge but the increase has been
more than offset by higher aluminium
prices. Restructuring of Aluminium
Metal is on track with approx. 110,000
tonnes of annual capacity to be closed
down by the end of 2006 and during
2007, thereby completing the closure
program of 180,000 tonnes of high-
cost primary production capacity.
The measures will significantly im-
prove Hydros smelter cost position.
The company is well positioned with
long-term power contracts extending
up to 2020 and alumina equity cover-
age increasing to 75 per cent in 2010.
Operational excellence remains a top
priority.
Hydro is pursuing a number of
take a much closer look at their Rus-
sian counterparts. Emerging multina-
tionals are already competing hard
for customers, talent and resources,
taking the more complacent global
players by surprise. Those Russian
companies that are able to transform
themselves into world-class com-
petitors will be able to determine the
shape of international business in
their sectors.
This is a summary of a paper edited by Rusal
in November 2006 entitled: The Russians
are coming: understanding emerging multi-
nationals; in cooperation with The Econo-
mist Intelligence Unit, 2006
Norsk Hydro, Dag Jenssen
Hydro is about to exit Automotive Com-
ponents, but will continue to focus on the
sectors Rolled Products, Extrusion Europe,
Extrusion Overseas, Building Systems and
Precision Tubing
growth opportunities in alumina and
metal. The planned Qatalum smelter,
a 50/50 joint venture between Qatar
Petroleum and Hydro, is on track with
construction start scheduled for fall
2007 and start-up of production in
late 2009. The capital expenditure es-
timate has been increased from 2.3 to
3.4 billion euros, on a 100 per cent ba-
sis, as a result of general cost increases
for key materials and construction, a
weaker USD/EUR exchange rate as
well as design changes. Final cost es-
timate and build decision are sched-
uled for summer 2007.
ALUMINIUM 1-2/2007

Novelis Korea invests in multi-alloy casting
Investment continues global roll-out of
breakthrough Novelis Fusion technology
Novelis Inc. announced that its
joint venture in Korea, Novelis Ko-
rea Ltd., will invest US$ 4.1 milli-
on to install Novelis Fusion casting
technology in its Ulsan, South
Korea, plant.
The Korean investment continues the
global roll-out of the breakthrough
technology which first went into pro-
duction in March 2006 at the Compa-
nys plant in Oswego, New York. In
September 2006, Novelis announced
that it will invest US$ 32 million in the
construction of a Novelis Fusion cast-
Novelis
A crane lifts a Novelis Fusion multi-alloy
aluminum ingot from the casting pit at the
companys Oswego, N.Y., facility
Executing Aluminium Products
portfolio restructuring
Cash generation in Aluminium Prod-
ucts has been solid during the first
nine months of 2006, but profitability
remains unsatisfactory. Operational
improvements have been achieved
in most areas, and the outlook for
Extrusion and Building Systems is
good. In addition to the agreements
to divest Automotive Castings and
Meridian Technologies, the process
for divesting Automotive Structures
has started.
ALUMINIUM 1-2/2007
house at its Sierre, Switzerland, facil-
ity. The Novelis Fusion casting centre
at Ulsan is expected to be operational
by mid-2007 and will have an initial
annual capacity of more than 25,000
tonnes. The existing configuration
of the Ulsan casting facilities allows
a rapid and cost-efficient conversion
to the Novelis Fusion process, said
Martha Brooks, Chief Operating Of-
ficer for Novelis Inc. And added, This
investment is further evidence of our
confidence in the Novelis Fusion tech-
nology and the positive response we
are receiving from the marketplace.
In North America, Novelis has con-
verted virtually all of its traditional
clad material to the new technolo-
gy. We are working with dozens of
customers around the globe on the
development of applications in mar-
kets such as automotive, architecture,
electronics and household applianc-
es, said Martha Brooks.
Traditional multi-alloy aluminium
ingots are produced using a manual
cladding process, and are limited to a
small range of alloys. Novelis Fusion
technology delivers both process and
product improvements, including the
ability to cast previously impossible
combinations of alloys.
Commercially, this investment
will open the door to a new range of
high-end product offerings in Asia,
Hydros magnesium plant in Canada
will be closed during first half of
2007, and the remaining magnesium
remelting plants will be divested.
ECONOMICS
said Jacquie Bartlett, Vice President,
Sales and Marketing, for Novelis Ko-
rea. With the Novelis Fusion tech-
nology, we will start by offering a full
range of high-quality brazing sheet
and fin stock products to local cus-
tomers that today must rely on im-
ports.
It was Novelis second major in-
vestment in South Korea last year. In
March 2006, the company announced
that it will invest US$ 30 million over
a two-year period to increase produc-
tion capacity at its Yeongju rolling
mill by 100,000 tonnes and expand
its capability in the beverage can end
market.
About Novelis Korea
Novelis Korea Limited is a joint ven-
ture company between Novelis Inc.
(68%), Taihan Electric Wire Co. Ltd.
(31%), and Hyundai Group (1%). Its
plants in Yeongju and Ulsan were
commissioned in 1993 to meet the
growing demand for rolled aluminium
products principally in Korea, China
and Southeast Asia. Including its cor-
porate office in Seoul, Novelis Korea
has more than 1,200 employees who
supply a broad range of high quality
products and services to its custom-
ers in Asia.
N
Rolled Products delivers consistently
strong cash flow, but industrial chal-
lenges remain.
N
27
 ECONOMICS
Alcoa to reposition downstream operations
Soft alloy extrusion joint venture
with Sapa group announced
Alcoa is to relocate several of its
downstream operations in order
to further improve returns and
profitability through a targeted re-
structuring of operations and the
creation of a soft alloy extrusion
joint venture. The joint venture
will become a global leader in the
aluminium extrusion business,
with an estimated turnover of US$
4 billion in 2006.
Following an extensive review of its
downstream operations, Alcoa has
signed a letter of intent with Norwe-
gian Orkla ASAs Sapa group to create
a joint venture that would combine
its soft alloy extrusion business with
Sapas profiles extruded aluminium
business, with the intention of even-
tually offering an IPO of the combined
entity. The new venture will be major-
ity owned by Orkla and operated by
Sapa. It is anticipated that the joint
venture will be formed by the end of
the first quarter 2007.
Alcoas soft alloy extrusion busi-
ness encompasses 22 facilities in eight
countries and about 6,400 employees.
In 2005, total soft alloy extrusion ship-
ments amounted to around 585,000
t, with revenues of approx. US$ 2.1
billion. Sapas extrusion business en-
compasses 18 facilities in 12 countries
and about 6,000 employees. In 2005
section shipments were 275,000 t and
revenues amounted to US$ 1.3 billion.
Alcoa will continue to operate its hard
alloy extrusion business which serves
the aerospace, automotive, and se-
Alcoa
Corporate centre of Alcoa, Pittsburgh
28
lected other markets. Separately, the
concern will begin the process to di-
vest the three soft alloy facilities not
included in the joint venture located
in Warren, Ohio, in Tifton, Georgia,
and in Plant City, Florida.
Alcoa Chairman and CEO Alain
Belda said, The combination of
these two operations provides many
opportunities to improve profitability
by leveraging the scale of a broader
global manufacturing system. He
added, Our overall downstream op-
erations have continued to improve
their financial performance the past
few years. We have leading positions
in key flat-rolled product segments
where we have grown 14% annually
since 2002 and where we are also in
a strong position to capture further
growth in China and Russia. Other
downstream operations such as Alcoa
Howmet and Alcoa Fastening Sys-
tems improved profitability by more
than 60% in 2005. And our forgings,
global building and construction and
hard alloy extrusion businesses are
solid performers. This move and our
continued focus upon continually
maximising returns should serve our
downstream operations well for the
next several years, said Belda.
Savings of US$ 125m
before taxes expected
As part of the review of its overall
downstream operations, Alcoa also
plans a targeted restructuring pro-
gramme in order to further increase
efficiency as well
as profitability. The
restructuring will
encompass plant
closures and conso-
lidations that will
affect some 6,700
positions across the
concerns global bu-
sinesses in 2007.
This programme is
expected to save
around US$ 125 million before taxes
on an annualised basis. Through the
first three quarters of 2006, Alcoa
generated more earnings than in any
full year of the companys history. In
order to continue to move forward,
we now need to take the difficult but
necessary restructuring steps that
will continue to maximise profitabil-
ity across the company, said Belda.
Included in the fourth quarter 2006
restructuring are the following major
components:
Flat rolled products (FRP): Restruc-
turing of the companys can stock op-
erations resulting in the elimination
of approx. 320 jobs, including the clo-
sure of the Swansea can stock facility
in UK. Conversion of the idle rolling
mill in San Antonio, Texas, into a tem-
porary flat rolled products technical
facility serving Alcoas global FRP
business.
Extruded and end products: Op-
timisation of the companys global
hard alloy extrusion production op-
erations which serve the aerospace,
automotive and industrial products
markets. This will result in the elimi-
nation of around 370 jobs in the US
and Europe.
Engineered solutions: Restruc-
turing and consolidation of the com-
panys automotive and light vehicle
wire harness and component opera-
tions, including closure of the manu-
facturing operations of the AFL Seixal
plant in Portugal and restructuring of
the AFL light vehicle and component
operations in the US and Mexico.
These measures will affect more than
4,800 jobs.
Packaging and consumer: Consoli-
dation of selected operations within
the companys global packaging pro-
duction to increase productivity, re-
sulting in the elimination of around
470 jobs.
Primary metals and alumina: Cuts
within the companys global primary
metals and alumina operations by ap-
prox. 330 jobs to further strengthen
the companys position on the global
cost curve. N
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y

Fig. 1: Patented electric preheater for cathode blocks

Almeq electric preheater for cathode blocks

J. D. Hansen, Langhus

The electromagnetic stability of

the liquid aluminium pad depends
on the uniformity of the electric
current passing through it from
above and below. Therefore, just
as every anode needs good electri-
cal connection to an anode rod, so
every cathode block needs good
electrical connection to a steel
cathode collector conductor bar.
Since it cannot be repaired in
service, the cathode connection
All illustrations: Almeq

must reliably last the lifetime of

the pot, and its fabrication is a vi-
tal step in pot assembly.

The steel bar is sealed into the cath-

ode blocks using a paste, glue or cast
iron. To improve the electrical con-
nection, this cathode block must be
preheated to about 700 C. Tradition-
ally this has been done by flame heat-
ing the assembly from outside. This
is not very efficient or convenient: it
involves substantial fuel costs, noise,
and fumes. Also, it requires close su-
pervision, as it tends to oxidise carbon
from the cathode blocks, there is a risk
of gas explosions. To overcome these
problems, Almeq invented an electric
Fig. 2: Clamping system
preheater for cathode elements be-
fore the rodding. Its key elements are
illustrated as follows.
A patent covers the principle of
electric resistance heating of cathode
blocks. The carbon blocks with steel
conductor bars are placed in an insu-
lated chamber, where the steel bars
are connected to an electric current of
between 4 kA and 7 kA. This uniformly
and heats the steel bar in programmed
stages to 700 C; the cathode blocks
reach 400 C and do not need more,
as they are already calcined. The fully
automated process has an accurate
clamping mechanism to introduce the
heating current. To avoid overheating
the copper clamps, these are water
cooled. If the cathode consists of a
split steel bar, the preheater station is
equipped with an electrical contact in
the middle to bridge the gap.

30 ALUMINIUM 1-2/2007
SPECIAL
Fig. 3: Process control
The process is controlled by thermo-
couples monitoring the temperature
in the steel bar and carbon cathode
block. The exact temperatures are set
according to the customers specifica-
tion.
Different methods are available for
feeding the carbon and steel assem-
blies to the preheater. Alternatives
range from a single loading wagon
to complete arrangements including
shot blasting and casting station.
Results in service
Four machines are in service, totalling
17 years of experience:
Country Place Customer
Iceland Hafnafjordur Icelandic Aluminium Company
Norway Husnes Sr-Norge Aluminium
UAE Dubai Dubai Aluminium Company
Iceland Grundartangi Nordural
The first machine installed replaced
propane gas heating at Isal, Iceland, in
1997, and it gave the following results:
yearly saving in energy: 1.28 GWh,
elimination of CO2: 360,000 kg/year,
saving in manpower: 2 men.
Five years later, a duplicate ma-
chine was installed at SRAL, Nor-
way, which uses identical cathode
blocks to Isal. In 2003, Almeq deliv-
ered an improved system to Dubai
Aluminium (Dubal). To increase pro-
ductivity, this system has two trolleys
to prepare the cathode blocks. Due to
changes in cathode design, the Dubal
preheater will be modified to handle
31
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
the new, bigger blocks. The latest in-
stallation was delivered to Nordural,
Iceland for the Phase III expansion
project. The system has been run-
ning for a year and has heated 6,000
cathode blocks. The results from the
system are as follows:
Previously, 400 kg of propane was
required to heat 6 cathode blocks. The
estimated cost of propane is 0.40 euros
per kg. With the electric preheater for
cathodes the required electrical con-
sumption is 600 kWh with an estimat-
ed cost of electricity of 0.04 euros per
kWh (In Iceland, the cost of electricity
is less than 1/3 of this). The savings for
heating 6 cathode blocks:
Year
1997
2002
2003
2005
Fig. 4: Feeding
Propane 0.40 x 400 = 160.00
Electricity 0.04 x 600 = 24.00
Saving per heating 136.00.
Besides this direct cost compari-
son, experience in service confirms a
range of advantages for the automated
system:
High power factor (cost )
No supervision needed during
procedure
No hazard to personnel nor
facilities
Low energy consumption
(1:5 reduction)
No noise
Negligible carbon oxidation
Uniform temperatures in the steel
bars and in the carbon blocks
Identical conditions prior to
each casting
Fully automated feeding
No exhaust gases.
Summary and Conclusion
Before cathodes blocks are assembled
into electrolysis pots, the steel con-
ductor bars must be sealed into them,
and then heated to ensure adequate
electrical conductivity.
Compared to the external gas or
oil burners traditionally used for this
preheating, electric resistance heating
from within is safe, clean, and reliable.
Experience in four smelters proves
that this automated system is amor-
tised by the fuel, operator and other
costs it saves.
Author
Jan D. Hansen is General Manager of Almeq
Norway AS, based in Langhus, Norway.
31
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y

AlPrg: a software tool for aluminium smelting

P. M. Entner, Sierre

AlPrg is a collection of computer

programmes (modules) for PCs
using interactive graphics to dis-
play the results of calculations
concerning aluminium produc-
tion by electrolysis. The user ap-
plies these modules among other
things to visualise how varying
the parameters will affect pot
operation. He can then choose
the best values to operate the
electrolytic cells of a potroom so
as to optimise the most important
technical and economic results.
This paper reports on the use of
All illustrations: Entner

one of these modules, namely the

Electrolyte Properties Module.
This module calculates the physi-
cal and chemical properties of the
cryolite electrolyte as a function
of its composition and tempera- Fig. 1: Layout of the User Interface of AlPrg. The figure shows 3 tab groups with the cal-
culation pages Technical Profitability Analysis, Aluminium Production and Pot Parameters
ture. The Electrolyte Properties
being selected. Two diagram panes namely the Pot Voltage Diagram Pane and the Electro-
Diagram Pane shows plots of these lyte Composition/Properties Diagrams Pane are docked on the programme user interface.
bath properties in function of the
electrolyte parameters. This plot This module shows the physical and ing on various parameters. Formed as
predicts the behaviour of the bath chemical properties of the cryolite graphical user interfaces (GUIs), the
after a parameter change, and so electrolyte, like the liquidus tempera- plots allow the user to change values
identifies the optimal bath com- ture or electrical conductivity. AlPrg on the plot by dragging their size rep-
position and bath temperature to determines these values in relation resentation with the mouse pointer.
operate the electrolytic cells. to the chemical composition and the AlPrg calculates the corresponding
temperature of the electrolytic bath. new resulting values and updates the
AlPrg was developed with the aim of The electrolyte properties diagram relevant pages and plot panes.
helping people occupied with alumin- pane shows diagrams of these bath The user selects pages or plot
ium production by electrolysis. AlPrg properties in function of various plots. panes by clicking on the correspond-
contains several modules that the These plots predict the behaviour of ing menu or tab items. He can arrange
user selects depending on the tasks the bath after a parameter change and several pages on the programme user
he wants to study. For instance, if he so help to determine the optimal bath interface and see them simultane-
wants to know how much aluminium composition and bath temperature. ously so as to study the calculation
a potroom is producing in one month, results. The diagram panes can float
then he uses the aluminium produc- Programme layout on the computer screen or they can
tion module. If he needs to find the set be docked, i.e. added on the AlPrg
value of the pot voltage, the alumina When the author of this paper worked user interface. The next figure (Fig. 1)
feeder setting or how much alumini- with Alusuisse and later with Alcan he depicts an example of the AlPrg user
um fluoride to add, he will apply the developed ElysePrg [1] a precursor of interface containing three tab groups
corresponding, obviously more com- AlPrg. AlPrg is, however, a completely and two diagram panes. From the tab
plex, modules of AlPrg. Finally if the new concept for this application, espe- groups the user has selected the tech-
user wants to improve the economic cially regarding the program features nical profitability analysis page, the
performance of the aluminium smelt- and program layout. AlPrg consists aluminium production page and the
ing plant, the profitability analysis of pages and diagram panes. In the pot parameter page. In addition he has
modules will help him to determine windows the user changes numerical docked the pot voltage diagram pane
those operational parameters to run values in input fields, and then AlPrg and the electrolyte composition/prop-
the plant in a better way. calculates the corresponding results. erties pane on the user interface.
This paper deals with the elec- The diagrams (plots) show graphical The user finds more information
trolyte properties module of AlPrg. representation of properties depend- about AlPrg in the conventional ac-

32 ALUMINIUM 1-2/2007
SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y

companying help system. He may also
consult the corresponding website [2]
that contains practically the same us-
ers guide and theoretical background
information.
The Electrolyte Composition/
Properties Page
Fig. 2 shows the electrolyte compo-
sition/properties page. In the upper
part of the page the user changes the
concentration values of the electrolyte
components of aluminium fluoride
(AlF3), calcium fluoride (CaF2), alu-
minium oxide (alumina Al2O3), lithi-
Fig. 2: Electrolyte Composition/Properties Page. In the upper part tum [4], Peterson
of the page the user may change the concentration values in the
input fields. The lower part contains the property values. The
user may select the authors of the corresponding equations that [7] or Dewing [8] to
AlPrg uses to calculate the properties.
um fluoride (LiF), magnesium fluoride
(MgF2) and potassium fluoride (KF).
The bath ratio is the weight ratio of
sodium fluoride over aluminium fluo-
ride. Aluminium oxide at anode effect
is the alumina concentration when
the anode effect occurs. The user can
suppress this parameter by inactivat-
ing the check box.
The lower part of the page contains
the values of the electrolyte proper-
ties, namely the liquidus temperature,
cosities of the electrolytic bath and of
the aluminium metal.
The bath temperature can be ex-
pressed as the liquidus temperature
plus the superheat. The user selects
as input value either the superheat
(as shown in Fig. 2) or the electrolyte
temperature. Selecting a value as in-
put means that it is constant for the
following calculations (the superheat
in Fig. 2) and the other depending
value (the bath temperature in Fig. 2)
is calculated correspondingly.
To determine the liquidus tempera-
ture, the electrical conductivity or the
densities the user can choose between
several relation-
ships published by
different authors. Fig. 4: The Electrolyte Composition/Properties Diagram Pane
docked on the AlPrg user interface. Small icon-like plots
Fig. 2 shows a Drop
represent the selected electrolyte property (the liquidus
Down Combo Box temperature in this figure) in function of the electrolyte
where the user has components. The user has selected the liquidus temperature
vs. aluminium fluoride content to be shown in the larger
selected the equa- property plot. The circles represent the current values of
tions of Solheim [3]. the electrolyte composition.
He could alterna-
tively also click on the liquidus temperature depends on
the names of Rs- these variables, the other parameters
staying constant. The small circles
[5], Bullard [6], Lee represent these constant concentra-
tion values shown on the electrolyte
choose the corre- composition/properties page.
sponding relations.
The theoretical part of the AlPrg Property plot
website [9] contains all the relations
and equations that AlPrg uses for its If the user wants to study an icon-
calculations. plot more profoundly he clicks on
the icon-plot with the mouse pointer
The Electrolyte Composition/ and the icon-plot expands to replace
Properties Plot the larger property plot. In Fig. 4 the
Fig. 4 shows the electrolyte compo-
sition/properties plot pane together
with the electrolyte composition/
properties page.

Icon plots

The idea of this plot pane

is to show a property of the
electrolytic bath in depend-
ence of the bath composi-
tion and the bath tempera-
Fig. 3: Drop Down Combo Box to select the authors of ture. The plot pane of Fig.
the relations that AlPrg uses to calculate the liquidus tem-
4 consists of small icon-like
perature. The user has chosen the equation of Solheim
[3] by clicking on the name with the mouse pointer. plots of the liquidus temper-
ature against the concentra-
the electrical conductivity, the maxi- tions of aluminium fluoride, calcium
mum alumina solubility, the total va- fluoride, aluminium oxide etc. From
pour pressure, the densities and vis- these plots the user can visualise how
Fig. 5: Liquidus temperature vs. Alumina Concentration
Property Plot. The user has clicked on the Al2O3 icon-plot
and the property plot shows the liquidus temperature vs.
the alumina concentration. The gray areas are the regions
where the alumina concentration is lower than anode effect
concentration (on the left side) or higher than the maxi-
mum alumina solubility (right side).
user has clicked on the aluminium
fluoride concentration icon-plot, and
consequently the property plot shows
the liquidus temperature in depend-
ence of the aluminium fluoride con-

33
ALUMINIUM 1-2/2007 33
ALUMINIUM 1-2/2007
 A L U M I N I U M S M E LT I N G I N D U S T R Y
centration between 0 and 30 weight
%. The circle represents the liquidus
temperature of 953.7 C at the alu-
minium fluoride concentration of 12
weight %.
Gray areas in the icon or property
plots are regions where values are not
available or not possible. Fig. 5 shows
the property plot of the liquidus tem-
perature vs. the alumina content. The
grey regions show where the alumina
concentration is smaller than the an-
ode effect concentration (on the left
side) or greater than the maximum
solubility of alumina in the electro-
lyte.
Electrolyte and aluminium
densities
As an example the following chapter
discusses the densities of the elec-
trolyte and of the liquid aluminium
metal. In the electrolytic production
of aluminium the density values es-
Fig. 6: Aluminium and Electrolyte Densities Plot Pane. The
user has clicked on the aluminium fluoride icon-plot, so that
the property plot shows the aluminium and electrolyte den-
sity vs. the aluminium fluoride concentration.
pecially the density difference be-
tween aluminium and electrolyte af-
fects the separation of the produced
aluminium metal from the bath. This
difference should be larger than 0.2
g/cm3 in order to prevent mixing and
to maintain good separation between
the metal pad and the electrolyte lay-
er. In the electrolyte and aluminium
density plot pane AlPrg shows simul-
taneously the densities of the liquid
aluminium metal and the liquid elec-
trolyte. In this way the user sees im-
mediately the influence of parameter
changes on the density difference.
Dragging
If the mouse pointer is over the prop-
erty plot and the user presses the right
mouse button a so-called value line
34
Fig. 7: Dragging of the Value Line. When the user holds down the right mouse button AlPrg
draws the so-called value line. When the user drags this line by moving the mouse, AlPrg
registers a new input value and plots new density values in the property and icon plots.
is drawn. When the user displaces plot (densities vs. superheat on Fig.
the mouse (dragging) the value line 6, 7) and the electrolyte temperature
follows this motion on the property plot (bath temperature vs. aluminium
plot. AlPrg registers this new concen- fluoride on Fig. 6, 7).
tration input value (5% aluminium Clicking on the superheat icon-
fluoride in Fig. 7) and calculates the plot ('T) AlPrg draws the correspond-
corresponding new density values in ing property plot, namely aluminium
the icon and property plots (and elec- and electrolyte density vs. superheat.
trolyte composition/properties page). By dragging the value circles, the user
If the user wants to change another can modify the input value of the su-
parameter, the lithium fluoride con- perheat.
centration, the procedure is the same. Since the last selected composi-
The user clicks on the lithium fluoride tion icon plot was the densities vs.
icon plot. This icon plot is then se- aluminium fluoride icon-plot, AlPrg
lected, i.e. AlPrg shows this plot in the shows in the bath temperature icon
main property plot. By again dragging plot how the electrolyte temperature
the value line with the mouse point- depends on aluminium fluoride con-
er, the user changes then the lithium centration.
fluoride concentration,
and AlPrg calculates the
corresponding density
values.
Temperature plots
The superheat, i.e. the
temperature difference
between the electrolyte Fig. 9: Property Plot of Densities vs. Superheat. The user has
temperature and the selected the superheat icon-plot of Fig. 6 and so AlPrg draws
the corresponding property plot densities vs. superheat.
liquidus temperature, is
a very important value for everyday If the electrolyte temperature is
pot operation. Sometimes some quite selected as input value on the elec-
puzzling events are observed, namely trolyte composition/properties page
that the superheat might be nega- (see Fig. 2, 3 and 4), then the electro-
tive (the electrolytic bath should be lyte composition/properties diagram
solid) even for a rather long time pe- pane shows the densities vs. electro-
riod. This effect is called the liquidus lyte temperature icon-plot (Fig. 11). By
enigma [10]. clicking on this icon plot, the user in-
If the superheat ('T) is selected as structs AlPrg to show the correspond-
input value on the electrolyte compo- ing aluminium and electrolyte density
sition/properties page (see Fig. 2, 3 vs. bath temperature property plot, as
and 4), then the electrolyte composi- well as the electrolyte temperature
tion/properties diagram pane shows plot (bath temperature vs. aluminium
two icon-plots, namely the superheat fluoride on Fig. 6, 7).
ALUMINIUM 1-2/2007
SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y

however also incorporated into other

Fig. 10: Property Plot of Bath Temperature vs. Aluminium Fluoride Concentration. The user
has selected the bath temperature icon-plot of Fig. 6, and so AlPrg draws the correspond-
ing property plot bath temperature vs. aluminium fluoride concentration.
Conclusions
This paper describes the calculation
page and the diagram pane of the elec-
trolyte properties module of AlPrg. In
the calculation page the user enters
or modifies in a rather conventional
way values in the corresponding input
fields, and AlPrg then determines the
corresponding electrolyte properties,
like liquidus temperature, electrical
conductivity etc. The diagram pane
shows graphical representations, i.e.
plot is a graphical user interface, i.e.
the user can change input values by
dragging the so called values line with
the mouse pointer to a new position
and value.
The user investigates in this way
the behaviour not only of those elec-
trolyte properties already described in
this paper (liquidus temperature and
densities), but also the electrical con-
ductivity (interesting for pot voltage
settings), maximal alumina solubility
(used for point feeder setting) , vapour
modules where it is needed, for in-
stance into pot voltage or the profit-
ability module. It works there in the
same interactive way as described in
this paper; this means the user can
change an input value either from the
key board on the electrolyte property
page, or else by dragging on the cor-
responding property plot. AlPrg then
recalculates other parameters and
updates the corresponding pages or
plot panes.
References
[1] P. M. Entner, New Feature of ElyseSem/
ElysePrg, Aluminium 75 (1999) 12, 1064-
1072
[2] http://www.peter-entner.com.
[3] A. Solheim, S. Rolseth, E. Skybakmoen,
L. Sten, . Sterten, T. Stre, Liquidus
Temperature and Alumina Solubility in
the System Na3AlF6-AlF3-LiF-CaF2-MgF2,
Light Metals (1995), 451-460.
[4] A. Rstum, A. Solheim, A. Sterten, Phase
Diagram Data in the System Na3AlF6-Li-
3
AlF6-AlF3-Al2O3. Part I: Liquidus Temper-
atures for Primary Cryolite Crystallisation,
Light Metals (1990), 311-316.
[5] R. D. Peterson, A. T. Tabereaux, Liqui-
dus Curves for the Cryolite-AlF3-CaF2-
Al2O3 System in Aluminum Cell Electroly-
tes, Light Metals (1987), 383-388.
[6] G. L. Bullard, D. D. Przybycien, DTA De-
termination of Bath Liquidus Temperatures:
Effect of LiF, Light Metals (1986), 437-443.
[7] S. S. Lee, K.-S. Lei, P. Xu, J. J. Brown
Jr., Determination of Melting Tempera-
tures and Al2O3 Solubilities for Hall Cell
Electrolyte Compositions, Light Metals
(1984), 841-855.
[8] E. W. Dewing, The Chemistry of the
Alumina Reduction Cell, Can. Metallurgi-
cal Quarterly (1974), 13 (No.4), 607-618;
JOM 53 (2001) 5, pp. 29-34.
[9] http://www.peter-entner.com/e/theo-
ry/thcontents.htm.
[10] B. P. Moxnes, A. Solheim, T. Stre, B.
E. Aga, L. Sten, The 'Liquidus Enigma'
revisited, Light Metals (2006), 285-290.

Author
Fig. 11: Densities vs. Electrolyte Temperature Property Plot. The user has selected the elec-
trolyte temperature as input value on the electrolyte composition/properties page. AlPrg Peter M. Entner has studied chemistry at
then shows the densities vs. electrolyte temperature icon- and property plot after appro- the University of Vienna. He pursued his
priate selection by the user. The shaded area is the region where the bath temperature is
lower or higher than the liquidus temperature +/- the maximum superheat (50 C).
studies at the University of Pennsyslvania
and University of Geneva (high tempera-
ture electrochemistry and crystallography).
small icon-plots, of how a selected pressure (necessary for environmen- He joined then Alusuisse that later became
property (the liquidus temperature, tal issues) and the viscosities of the Alcan to work on research and develop-
for instance) depends on the elec- liquid aluminium pad and electrolyte ment projects about aluminium smelting.
Being retired, Peters passion for bytes and
trolyte composition values and the (used for hydrodynamic studies). pixels keeps him busy to work on software
bath temperature. The user selects This paper describes the electro- that might be useful for the members of the
an icon-plot to be drawn in the larger lyte properties module as a stand- aluminium smelting community.
and more precise property plot. This alone programme. This module is

35
ALUMINIUM 1-2/2007 35
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Honoured by The Electrochemical Society
Vittorio de Nora receives 2006 Acheson
Award for lifetime career achievements
Vittorio de Nora has been hon-
oured as the recipient of The
Electrochemical Society (ECS)
2006 Edward Goodrich Acheson
Award. The Acheson Award was
established in 1928 to recognise
distinguished contributions which
advance objects, purposes or ac-
tivities of ECS. Requirements for
receiving the award are distin-
guished services to the Society,
as well as distinguished scientific
discoveries or inventions in elec-
trochemical or solid state science
and technology.
Vittorio de Nora has dedicated his
career to scientific research in the
field of electrochemistry, including
in particular the fields of chlorine-al-
kali and aluminium production. Dr. de
Noras research achievements centre
on his efforts to find a feasible inert
anode, that is an anode that operates
in a cell without becoming corroded
as part of the electrochemical process,
and which could be used to replace
carbon anodes in electrochemical
cells. He succeeded, first with the
Dimensionally Stable Anode (DSA)
that revolutionised chlorine-alkali
production and other electrochemi-
Moltech
cal industries. By saving electrical
energy, improving cell operation and
eliminating or substantially reducing
pollution, the DSA has contributed to
a predominant position for electro-
chemistry worldwide.
Recently, Dr. de Nora and his
scientific team based in the modern
laboratories purpose-built in the
Swiss Valais, have developed the pro-
totype of a de Nora inert anode for
aluminium production. Inert anodes
not only eliminate serious pollution
problems, including carbon dioxide,
carbon monoxide and perfluorocar-
bon emissions from carbon anodes,
but also improve energy efficiency of
inert anodes in electrowinning cells
and also significantly reduce operat-
ing costs.
36
Biographical Note
Vittorio de Nora was born in Alta-
mura, Italy, on 11 November 1912.
He attended middle school, graduat-
ing in 1929, and was admitted to the
Royal Politecnico Institute of Milan in
October of the same year, where he
received a doctorate in Electrochemi-
cal Engineering with full honours in
1935. In 1936, he was chosen to be
Professor of Physical Chemistry and
Electrochemistry at the Royal Politec-
nico Institute but he decided to spend
two years to carry out research at
Kings College, University of London,
with the famous Professor Allmand.
Vittorio de Nora
Later, at the Hochschule of Dresden,
he worked for one year with Profes-
sor Muller, who decided to delay his
retirement in order to accept the chal-
lenge of working with de Nora.
Leaving Dresden in 1937, Vittorio
de Nora went to the United States,
where he enrolled at Lehigh Univer-
sity in Pennsylvania. While at Lehigh,
he became one of the first members
of ECS, and today he has the distinc-
tion of being the Society member with
the longest membership record. He
chose Lehigh in order to work with
Professor Butts and the results of his
research earned him a Ph.D. in Physi-
cal Chemistry in just nine months.
Vittorio de Nora is a Volta Fellow, a
Weston Fellow and a Case Centennial
Scholar. He was elected an Honorary
Member of ECS in 1982, and he be-
came a Fellow of the Society in 1992
in recognition of his contributions
to science and electrochemical en-
gineering. Case Western University,
Lehigh University and the University
of Cincinnati have conferred on him
the honorary degree of Doctor of Sci-
ence. He was one of the five found-
ers of International Physicians for the
Prevention of Nuclear War (IPPNW),
to whose activities he contributes as
the only non-medical founder. IPP-
NW received the Nobel Peace Prize
in 1985.
Vittorio de Nora has inspired
noteworthy technical achievements
by encouraging research in electro-
chemistry through his endowment of
the annual Electrochemical Society
Vittorio de Nora Award for distin-
guished contributions in the field.
He is the author of hundreds of
worldwide patents related to indus-
trial electrochemistry. His most im-
portant patents in the chlorine-alkali
field include not only the DSA itself,
but also the great advantage of a new
membrane cell design, which direct-
ly produced concentrated salt-free
caustic and also eliminated pollution,
particularly by eliminating mercury
cathodes and asbestos diaphragms.
De Nora companies have also de-
veloped the bi-polar chlorine cell,
built plants producing one-third of
the worlds chlorine production,
including the largest chlorine cell
(450,000 A), still the largest electro-
chemical cell ever built, and have also
constructed the worlds largest water
electrolysis plant having heavy water
as a by-product. N
For subscribers
www.alu-archiv.de
Knowledge with
a lasting impact!
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y

Aumund cooling conveyor for

hot bath material
M. Coopmann, Rheinberg

In the course of more than 80

years the Aumund Group has
earned its reputation as a special-
ist in supplying equipment for raw
material handling in the cement
industry, in the iron and steel as
well as in the primary aluminium
industry. From its headquarters
in Rheinberg, Germany, the Au-
mund Group has integrated the
All illustrations: Aumund

companies Schade Lagertechnik

GmbH at Herne in Germany, and
B&W Handling Ltd. at Ely, UK, in
the last years. With more than
10.000 machines installed in over
100 countries, the Group continu- Fig. 1: Fluoride emissions
ously faces market challenges and
tries new solutions. Especially the usually been collected in containers of time not longer than 12 hours. Prior
handling of hot and abrasive bulk and allowed to cool naturally. Due to to this cooling on an Aumund deep-
materials in the steel and primary the thickness of the layer of hot bath drawn pan conveyor, a specially de-
aluminium industry puts severe material in these containers, there is signed hot bath crusher from SMV A/S
requirements on the conveying no guarantee that the bath lumps will receives up to 850 C hot bath mate-
technique. Aumund already se- have cooled below 100 C even after rial and crushes it down to a lump size
cured an entry into the Guinness 24 hours of cooling time. However, of about 200 mm. Directly underneath
world record book for supplying before further processing, the mate- the hot bath crusher, the Aumund
of the longest bucket apron con- rial must cool down to below 70 to cooling conveyor is connected and re-
veyor for the transport of 900 C 80 C. Special coolers have been tried
hot direct reduced iron. to cool down the bath material to the
required temperature but without
To solve a particular problem in con- success.
veying technique Aumund invented In order to give the new anode good
a customer-specific solution in 1995 starting conditions, the solid bath sur-
for the aluminium smelting plant face has to be cleared from under it.
SR Norge Aluminium in Norway. This allows high current efficiency
It was developed with the manager and stable pot operation. Previously,
of the engineering department of the point feeding prebake technology did
smelting plant at that time and with not employ side breaking operation,
a Norwegian specialist for hot mate- so this bath material was stored in the
rial crushers, and it became the first service area of the pot. The crust with
economical and efficient solution for alumina and bath material was then Fig. 2: Covered conveyor connected to dry
scrubbing system
the clean handling of 850 C hot bath later broken into the liquid bath by
material. Since then this concept has the tools of the crust breaker vehicle,
meanwhile been successfully used for while fluoride gases escaped uncon- ceives the red-hot bath material. With
five units in other European smelting trolled. a variable speed between 0.15 m/min
plants. and 0.5 m/min the conveyor works
Solution and functional like a moveable storage and is able to
Problem description adapt to the discontinuous operation
of a smelting plant. After a distance
When using the prebake technology, For defined cooling of bath material, of 95 m, approximately 3 tonnes per
anode butts are removed together with Aumund developed a solution de- hour bath material is finally cooled
a substantial quantity of hot bath ma- signed to cool down hot bath material down on a 1400 mm wide conveyor to
terial. This fluoride-rich material has from 850 C to 80 C within a period approximately 80 C and is ready for

38 ALUMINIUM 1-2/2007
SPECIAL
further processing in the bath treat-
ment plant.
Research on the process of
conveying hot bath material
HF-emissions under control
HF-measurements at SR Norge Alu-
minium in 2005 have shown that the
HF-gases evaporate into the environ-
ment at temperatures above approx.
400 C material temperature and thus
risk damaging the health of employ-
ees in the potroom. At the tipping
point already, where the 850 C hot
Fig. 3: Conveyor section with heat
protection box and data logger inside
bath material is fed into the crusher,
there is a suction point which leads
the emitting HF-gases into the existing
dry scrubbing system. As the cooling
process progresses, the emissions of
the HF-gases progressively decrease,
until they finally become negligible
small for a bath material temperature
below 400 C (Fig. 1).
Moreover, the cooling conveyor is
covered by a hood and connected to
the existing dry scrubbing system via
several suction points (Fig. 2). Meas-
urements show that the suction sys-
tem absorbs approx. 60 g per tonne
of bath emissions on average during
a 3-shift operation.
Investigations of the cooling
characteristics of hot bath
material
In contrast to capacity needs in 1995
to cool 2.5 t/h of bath material, Au-
mund nowadays receives inquiries
calling for up to 36 t/h bath mate-
rial cooling and conveying capacity.
Calculating such applications in the
conventional way would lead to un-
economical solutions for our custom-
39
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
ers, and thus to higher investments in
infrastructure, civil work, etc.
Based on these requirements, Au-
mund started investigations at the pri-
mary aluminium smelter of Slovalco
in 2006. Since 2002 an Aumund cool-
ing conveyor had already been oper-
ating at the Slovalco plant to handle
hot bath material. At our works in
Germany a new conveyor section
was equipped with a Data logger and
six thermocouples (Fig. 3) and then
installed in the conveyor operating at
Slovalco.
The measurements taken during
the normal daily operation of the pri-
mary aluminium smelter provided us
with valuable data for further investi-
gations and led to a new Thermody-
namical Calculation Software (TCS).
This new TC-Software (Fig. 4) has
now replaced the old conventional
way of designing cooling conveyors
and is based on the following param-
eters:
material layer height
air flow above the conveyor
number of suction points
conveyor width
conveyor speed
lump size of bath material.
As a theoretical reflection, we used
the new TC-Software to recalculate
our first installation at SR Norge
Aluminium. Compared with our
original figures, the result would
have allowed a reduction in length
by 1/3 while doubling the conveyor
speed and reducing by half the layer
height of bath material. An additional
advantage of the new TC-Software is
the option to adapt and incorporate
Fig. 4: Cooling curve of bath material
restrictions in conveyor length or air
flow capabilities, according to our
customers references.
Benefits and advantages of the
Aumund cooling system
Reduction of investment cost in
infrastructure, such as avoiding
the need for a building to store
bath skips while the bath is cool-
ing prior to crushing;
No need for skips to cool bath
Reduction of operating cost
(no double handling of the skips
and associated vehicles and
operators)
Increased rate of automation
Clean bath handling
Defined cooling of bath material
Fluoride gases removed by
controlled suction;
Significantly increased safety and
health conditions in the potrooms
Improved environmental
conditions.
References
1995 SR Norge Aluminium, Norway
2002 SR Norge Aluminium, Norway
2002 Slovalco Aluminium, Slovakia
2002 Alcan Icelandic Aluminium,
Iceland
2006 Nordural Aluminium, Iceland
2006 Fjardal Smelter, Iceland
2007 Trimet Aluminium, Germany
Author
Marco Coopmann is Sales Manager, Divi-
sion Metallurgy of Aumund Frdertechnik
based in Rheinberg, Germany.
39
ALUMINIUM 1-2/2007
 A L U M I N I U M S M E LT I N G I N D U S T R Y
Advances in gas suspension calcination technology
B. E. Raahauge, Copenhagen
The principle of the gas suspen-
sion calciner (GSC) was develo-
ped by F. L. Smidth & Co. in the
early 1970s for pre-calcination
of cement raw meal (d50 = 10 to
20 m), as feed to the rotary kiln
burning the final cement clinker.
Following the successful commis-
sioning of the first 4,600 tpd rotary
kiln with pre-calciner in 1976, F.
L. Smidth decided to develop the
GSC technology for application
within the alumina industry. The
state of the art of the GSC tech-
nology in commercial operation
producing smelter grade alumina
(SGA) covers a capacity range
from 820 to 4,500 tpd of SGA.
The economics of bag house versus
electrostatic precipitators for meet-
ing environmental requirements have
changed over the past 20 years. This
paper describes developments since
the first 850 tpd GSC unit for alumina
was started up in 1986.
GSC for smelter grade alumina
(SGA) production
The GSC furnace comprises a cylin-
drical vessel with a conical bottom to
let in pressurized air or gas, as well
as a hot cyclone to separate of solids
All illustrations: F.L.Smidth
Fig. 1: Gas suspension calciner furnace and
cyclone (HFO: heavy fuel oil; SGA: smelter
grade alumina)
40
Fig. 2: Principle flow sheet for gas suspension calciner unit bag house and booster fan
from the outlet gas. A series of cool-
ing cyclones recover heat from the
calcined SGA to preheat air and fuel,
while a series of heating cyclones
recover heat from the combustion
gases to dry, preheat, and pre-calcine
the hydrate feed. The GSC furnace is
refractory lined and operates at a tem-
perature in the 950 to 1150 C range.
Preheated alumina enters the GSC
furnace at a temperature ranging from
320 to 370 C in a direction parallel
to the conical bottom of the furnace.
Preheated air enters from the cooler
at a temperature of 700 to 800 C and
is used to burn the fuel. The operat-
ing temperature chosen for the GSC
furnace and hot cyclone depends on
what degree of calcination the alumina
requires and on how long it stays hot
in the equipment downstream of the
hot separation cyclone. The operating
temperature can be lowered when
the GSC furnace and hot cyclone is
retrofitted behind a rotary kiln to act
as cooler (GSC retrofit), or if the hot
separation cyclone is equipped with
a fluidized holding vessel. The higher
operating temperature range is used
when alumina from the hot cyclone
discharges into a four (4) stage cy-
clone cooler. The GSC units are de-
signed for an overall pressure drop of
8 to 11 kPa before the gas dedusting
equipment. The specific power con-
sumption of 20 to 24 kWh per tonne
alumina depends on the type of gas
de-dusting equipment, the type of
fuel used, and whether a forced draft
booster fan is installed on the clean air
side. The specific heat consumption is
about 3.2 to 3.4 GJ per tonne alumina,
depending on moisture content in the
hydrate feed and on the type of fuel
used.
Thermal energy options for
calcination
The GSC units in operation today use
either heavy fuel oil (HFO), natural
gas, or coal gas as fuel. Since all the
combustion air is preheated by cool-
ing the alumina, the air flow through
a calciner, and thus the excess air
factor, has little impact on the energy
requirements. If more air enters the
cooling section, then more energy
will be recovered from the alumina,
but this is mostly offset by an increase
in the volume of hot gas lost to the
stack.
However, when using coal gas,
the losses to the stack will be higher
than for heavy fuel oil and for natu-
ral gas, because coal gas produces a
much greater volume of combustion
gases per unit of combustion heat.
This means that large volumes of coal
gas must be heated to calcining tem-
ALUMINIUM 1-2/2007
SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y

perature, further reducing the energy requires any

efficiency. The relatively low volume particulate
of air for burning coal gas results in filter technol-
a relatively higher loss of potentially ogy to achieve
recoverable heat to the cooling water higher clean-
(less recovery of heat from the alu- ing efficiency
mina). and on-line
Compared to natural gas, heavy availability, as
fuel oil has the disadvantage of requir- the allowed
ing a significant investment in storage emission level
and oil heating equipment. This, along is lowered
with the potential restrictions regard- year by year.
ing sulfur emissions, makes heavy fuel Most alu-
oil less attractive than natural gas as mina calcin- Fig. 3: 3 x 4500 tpd GSC units at Queensland Alumina Ltd.
a fuel for alumina calciners, although ers decured equipped with bag houses
the latters higher heating value (HHV) environmental
is 4 to 5% less per unit heat utilized by compliance by using electrostatic pre- correct start and stop procedures. The
combustion (LHV). Overall, coal gas cipitators (ESP), which until recently table below compares process data, a
increases the specific heat consump- were the state-of-the-art equipment. fabric filter and an ESP to achieve the
tion of GSC units with 6 to 7% when However, the bag house, or fabric fil- same level of emissions for a specific
compared to GSC units using heavy ter, is now considered an attractive
fuel oil or natural gas. economic alternative. The electrostat- Gas flow [Nm3/min] 10,9
Temperature [C] 155-240
Typical lower Combustion air Combustion gas HHV/ Outlet emission [mg/Nm3, dry] 30
Fuel type heating value theoretical volu- theoretical volu- LHV
(LHV) me (Nm3/ GJ) me (Nm3/ GJ) Tab. 2: Overall process data for a typical
gas suspension calciner filter plant
Heavy fuel oil 40.485 MJ/kg 264 279 1.061
Natural gas 37.345 MJ/Nm3 253 281 1.107
GSC unit. Both technologies have
Coal gas 6.530 MJ/Nm3 208 326 1.058
been selected to meet the same envi-
Tab. 1: Properties for alternative fuels used in calciner operation ronmental performance for the same
process conditions (i.e. flow, tempera-
However, at todays high energy ic precipitator loses competitiveness ture and pressure) when applying the
cost ranging from 3.3 euros per GJ for at lower outlet emission levels. This is same local conditions (i.e. wind load,
coal to 7.5 euros per GJ for oil, coal because it needs more electrical fields earthquake load).
gas may be a viable economic alterna- in the filter, which increases the as- The table below shows that the
tive to natural gas and HFO as fuel for sociated total installed cost. fabric filter is lower in capex (initial
new GSC units wherever coal is read- On the other hand, the total in- investment cost) compared with the
ily available. This is the case in many stalled cost of a fabric filter will gen- ESP. However the opex (operational
countries such as China, where most erally not change when the required cost) for the fabric filter is higher than
of the GSC units installed use coal gas emission is lowered. This is because the opex cost for the ESP. The opex for
as fuel. Preliminary economic analy- the outlet emission do not depend the fabric filter depends on the type
sis suggests that the pay-back time for very much on the air to cloth ratio. of filter media used and obviously on
a coal gasification plant is about one The major environmental advan- its lifetime. This data for capex and
year. tage of the fabric filter is its ability opex has been entered into a NPV (net
Finally it should be noted that coal to maintain envi-
gas produces 16 to 17 per cent more ronmental compli- Capex (capital expenditure) US$ Fabric Electrostatic
combustion gas volume when com- ance even when Supply cost 1,320,000 1,334,000
Installation cost 656 1,407,000
pared to natural gas and heavy fuel the high voltage Total capex, US$ Flange/Flange 1,976,000 2,741,000
oil, which requires relatively larger power supply fails. Opex (operational expenditure)
equipment for dedusting the calciner The electrostatic Bag life: assumed to be 3 years, cage life
exhaust gases to an acceptable emis- filter has, however, is assumed to be 2 set of bags
sion level. a higher degree of Pressure drop, mm WG 150 25
Power consumption, fan, kW 302 50
robustness in case Power consumption, hopper heaters, kW 24 58
Trends in air pollution control: of deviations from Power consumption, T/R set, kW NA 184
bag house versus electrostatic normal process pa- Power consumption, compressor, kW 25 NA

precipitator rameters, whereas Total opex, US$/year, 230,000 138,000

the fabric filter is based on 0.06 US$/kWh
The trend towards increasing en- sensitive to excess Tab. 3: Capex and opex for a fabric filter versus electrostatic
vironmental awareness worldwide temperature and in- precipitator

41
ALUMINIUM 1-2/2007 41
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
present value) cost analysis made for
a 20 year period.
The result is a break-even point
after approximately nine years before
the ESP becomes the lower cost al-
ternative.
Anyway, the major environmental
advantage of the fabric filter is its abil-
Anode rod repair and manufacture
D. Madden and B. Dalton, Gladstone
The anode rod was developed to
coincide with the introduction
of the prebaked anode and the
advent of prebake cell technology.
The early development phase gen-
erally consisted of a copper stem
joined to a steel pin or stub via
a bolted connection. The second
generation saw the introduction of
an aluminium stem joined to the
steel yoke. This connection was
achieved through the use of a bi-
metallic joint, commonly referred
to as a transition joint. The bolted
stub connection was replaced by a
welded connection and became an
integral part of a cast steel yoke.
The copper stem anode rod evolved
with the introduction of a welded
connection from the stem to the yoke.
This generation of anode rod also saw
the introduction of a multi pin yoke.
Generally this generation design has
survived through to todays technol-
ogy. The changes to the anode rod
have mainly been attributed to the in-
creases in line amperage necessitating
the use of much larger anodes.
Upgrading existing anode rod
fleets
The industry has seen extremely large
increases in line amperage and cur-
rent efficiencies. In order for existing
plants to stay competitive with new
smelters, they have increased their
amperage. We are seeing plants that
were designed for 100 to 150 kA now
running at 200 to 250 kA.
To achieve these increases, vari-
ous modifications were carried out.
42
ity to maintain environmental compli-
ance even in situations when the high
voltage power supply fails. And this
feature may overrule any economic
disadvantage over the long term, as
the local population will not allow any
temporary dust emissions, whatever
the cause.
In some cases the original anode rod
was modified:
Extra stubs added
Stub size increased
Transition joint type changed
Offsets in anode rod.
These changes did not necessarily re-
sult in the optimum rod design, but
with a typical inventory of 10,000
plus rods in an older smelter pro-
ducing 100,000 to 200,000 tonnes of
metal, modification is sometimes the
only viable option. As line amperages
further increase the anode rod may
require redesign; however, the deci-
sion to pursue this route will need
careful planning, as major, expensive
changes to other areas of the plant
may be required.
Current day anode rods
Typical materials used in modern-day
anode rods are transition joint (roll
bonded, aluminium to steel), yoke
(cast steel or fabricated mild steel),
stub (mild steel).
Author
Benny E. Raahauge, MSc (Chem. Eng.) has
worked since 1976 with development,
marketing and sales of the gas suspension
calcination technology for alumina. His
current position is General Manager, Alu-
mina & Pyro Technology, at FFE Minerals
Denmark A/S, based in Copenhagen.
Holcan
The design of the anode rod should
take into account:
Current carrying capacity
Mechanical strength
Choice of material
Ease of manufacture
Life of anode rod
Ease of repair
Cost of repair
Electrical resistance
Initial cost
Cell thermal requirements.
In recent years the industry has set-
tled on aluminium rods as a standard
compared to copper rods. This seems
due to a combination of factors:
Aluminium is slightly cheaper for
the same electrical performance
The larger section area of the alu-
minium rod is mechanically more ro-
bust
Aluminium rods last longer, typi-
cally more than 15 years compared to
often less than 7 years for copper
Supports the aluminium industry.
The procedure to manufacture an an-
ode rod is relatively straightforward.
ALUMINIUM 1-2/2007
SPECIAL
The cost to manufacture the yoke is
generally driven by up-front costs,
with far less consideration given to
on-going repair costs once the plant
is in operation. A cast steel yoke com-
plete with stub may cost 60 to 70%
more than a fabricated yoke.
On a plant with 14,000 new assem-
blies, this could represent savings of
US$ 3-4 million. Depending on the
fabricated yoke design, however, the
potential for extra repairs due to poor
design could easily cost the operating
plant the construction savings within
a few years of operation. These costs
could be incurred by:
Failed stub welds from either poor
welds or operational stresses
Full stub replacement versus par-
tial stub replacement
Twisting of assemblies once intro-
duced into the cell, due to welding
stresses not being addressed during
manufacture; increasing repair needs
and increasing voltage losses during
operation due to poor fit of stubs in
the stub holes.
Economics of rod repair
Cost of repair: On a modern day pot-
line of 280,000 tpy with a 180 mm
stub, the cost of repair can be in the
millions of dollars per year. Reduc-
ing repair costs is naturally a target
for many smelter operators. There are
means by which rod repair costs can
be reduced as shown in the exam-
ple below. There are also pitfalls in
attempting to reduce repair costs as
discussed in the next section Cost of
not repairing.
Example: If a 280,000 tpy potline
repairing 12,000 stubs per year were
to convert from a full stub replace-
ment to a partial stub replacement,
then savings in steel consumption,
based on a price of US$ 1,000 per
tonne, will be in the order of US$
290,000 per year.
This repair saving must be set
against a slight increase in voltage (4
mV) across the extra weld, amount-
ing to US$ 90,000 extra power cost
(at US$ 0.025 per kWh).
This shows that the gains from
adopting a partial stub replacement
far out weigh the extra cost in power
due to extra weld resistance a net
43
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
saving of US$ 200,000 per year for the
smelter.
Cost of not repairing: For the smelt-
er, the cost of rod repair is immediate
and tangible. There is, however, a hid-
den cost the cost of reduced oper-
ating performance (increased voltage
losses and changed thermal perform-
ance) due to poorly maintained and
repaired assemblies. Typical defects
which lead to reduced anode assem-
bly performance include:
Reduced stub diameter in the stub
hole
Reduced stub diameter above the
stub hole
Stub not central in stub hole
Stub not seated flat on the base of
stub hole
Reduced yoke arm section.
For illustrative purposes: It is estimat-
ed for the 280,000 tpy potline that, if
all stubs were allowed to drop from
180 mm to an average diameter of 160
mm within the stub hole, then the ad-
ditional voltage loss (40 mV) would
consume US$ 900,000 of power per
year (at US$ 0.025 per kWh). This
example highlights the importance of
maintaining the rod fleet.
The smelter operator must, how-
ever, be careful in setting rod rejec-
tion criteria the temptation to un-
der-repair anode rods, so as to reduce
the obvious costs of rod repair, could
ultimately be penalizing the smelters
total cost performance. But too strict
criteria will waste money in unneces-
sary repairs. Typically there is a trade
off between yearly repair costs and
the assembly performance as illus-
trated in the graph.
Repair methods for partial stub
replacement
To perform partial stub replacement
repair, three systems are compared:
Holcan stub welding system, friction
welding, robotic welding.
Holcan welding system: This low-
cost system has been in use for 20
years and employs the MIG (GMAW)
welding method in a semi-automatic
mode. It is very forgiving for out-of-
tolerance dimensions of the anode
rods already subjected to the opera-
tional stresses, and suggests the use
of flame cutting over sawing.
Friction welding: Due to very high
capital start up costs, this process is
more suited to being an owners re-
pair. A contractor would find it dif-
ficult to justify the cost of installing
this equipment. Close tolerances are
required to achieve a sound weld.
Generally it requires saw cutting of
the old stub, which is often problem-
atic and expensive.
Robotic welding: This system can
perform poorly with out-of-tolerance
anode rods, and will require a skilled
workforce to programme the robot.
Additionally it generally requires saw
cutting, which is problematic as stated
previously.
Conclusion
Particular attention should be paid to
the design of the anode rod yoke, as
regards to future repair costs a poor
design will lead to excessive repair
work which can easily consume ini-
tial capital savings. The repair meth-
ods chosen should take into account
all the costs and the methods that will
be adopted to complete these repairs.
Often reduced material usage, e.g
steel, can easily outweigh other costs.
Evaluate the hidden costs which
would arise if the stub, yoke and rod
condition deteriorate pick rejection
criteria which gives the lowest overall
cost to the smelter.
Accuracy of information
Given the many assumptions and
types of calculations, it is recom-
mended that these results be consid-
ered as order of magnitude estimates
only. It is recommended that actual
test data be gather under normal op-
erating conditions.
Authors
Dan Madden is the Managing Director of
Holcan Constructions Pty. Ltd. and has
worked in the aluminium industry for 28
years. He advises the industry on the man-
ufacture and fabrication of anode rods.
Bill Dalton has spent 10 years as a Senior
Research Engineer with Comalco and a fur-
ther 5 years as consultant to the aluminium
and wider metals industries. He is also an
expert in due diligence and production
cost analysis for the aluminium industry.
43
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Integrated continuous billet processing
F. Niedermair, Braunau
Developed in the 1970s by Hert-
wich Engineering (HE), continu-
ous billet processing plants have
become the accepted standard for
the processing of extrusion billets.
Today more than 60% of world-
wide production of extrusion bil-
let pass through such a HE plant,
which englobes inspection/QA,
HE.C-homogenisation, sawing, and
packaging.
This extraordinary success stems
from a number of clear advantages:
Perfectly uniform metallurgical
property of billet due to precise
and reproducible temperature
regime during heating, holding
and cooling
Combination of various process
steps into one fully automated,
continuous process, hence
substantial labour savings
All equipment components fully
compatible, because developed,
designed and built by HE
Plants built to latest
state-of-the-art technology,
80 such plants in operation,
HE-CIP, Continuous Improvement
Process.
HE extrusion billet plants are cus-
tom-designed to meet individual
requirements of clients, in terms of
throughput, floor area and technical
features.
Description of a modern plant
Description of a modern plant (60.000
to 120.000 tpy) with the emphasis on
technical features, novelties and spe-
cific options (Fig. 1):
The fully automated processing
sequence starts with laydown of cast
lengths of extrusion ingot on the en-
try table. From there logs are moved
over a storage conveyor to the inspec-
tion station, for visual inspection for
surface defects and for ultrasonic in-
spection (UT) for centre cracks and
inclusions. For extrusion billets the
linear UT station is adequate, while
billets destined for aircraft or auto-
44
All illustrations: Hertwich Engineering
Fig. 1: Typical plant layout
motive components are inspected Heating
with the helical method, whereby
the entire cylindrical billet volume is In the heating zone of the furnace,
inspected, incl. surface defects with extrusion-quality logs are heated to
perpendicular and angular probes. homogenizing temperature within 1,5
Logs are rotated while several probes to 2,5 hours, holding times may range
move along the billet surface, each between 2 to 4 hours (blue curve).
probe inspects only its section of the However, certain plants have been
log. This arrangement is necessary to built to meet different, special heat-
achieve the required throughput. Fur- ing requirements (Fig. 4).
thermore the helical UT is designed to For instance a plant in Scandinavia
meet the requirements of ASTM B 594 processes hard ZnMg alloys. This fur-
Class A or B respectively. nace is capable of slow heating in the
HE has achieved market leader- critical temperature range to avoid de-
ship with such ultrasonic inspection velopment of cracks due to inner ten-
stations. Fault sizes as small as 1,2 sions (red line vs. standard blue line).
mm FBH can be detected.
Data of UT-inspection-re-
sults for each individual
billet is recorded and re-
mains attached to the
billet throughout the sys-
tem (log-tracking). For
instance, a centre crack
detected in a certain log
causes the integrated billet
saw to automatically re-
move and scrap the faulty
section of the log (Figs. 2 Fig. 2: Linear testing
and 3).
A storage conveyor pro-
vides adequate log storage
between (UT) inspection
and continuous homogeni-
sing furnace. For reduced
noise, logs are lifted and
lowered during transfer,
no rolling is permitted. Helical testing
ALUMINIUM 1-2/2007
SPECIAL
Fig. 4: Heating curves
blue: standard, red: special slow heating
Cooling
Cooling after homogenising is an im-
portant aspect for extrudability and
mechanical properties of billets. Many
different cooling regimes are in use,
depending on metallurgical require-
ments and clients recipes, hence a
wealth of different coolers have been
built to date (Fig. 5).
Temperature (C)
Time (min)
Fig. 5: Cooling curves
Line a shows cooling by water
quench. With AlMgSi alloys, Mg2Si
thereby remains completely dissolved.
Line b represents cooling in
very intense air flow, with cooling
rates 600 to 800 C/hour.
Line c shows the log temperature
during cooling in a moderate airflow,
whereby cooling rates can be adjusted
350 to 550 K/hour.
The majority of plants built to
date are designed and equipped for
such cooling rates, as these meet the
45
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
requirements of
mainstream extrud-
ers.
Line d portrays
step-cooling. Only
one of our plants is
equipped for this
type of cooling.
However, due to the
associated impact
on extrudability
this cooling regime
is not applied in
practice.
Line e shows extremely slow cool-
ing in the range 75 to 150 C per hour,
which is required for certain special
alloys. Such slow cooling rates can-
not be achieved simply, not even with
stagnant air, but require closed cool-
ing chambers with several zones of
different air temperatures.
In accordance with this variety of
cooling regimes, actual cooling sta-
tions vary much in design and con-
struction. We distinguish between
open and closed type coolers, and
even coolers with built in heating de-
vices.
For certain countries with cold
climate we have built cooling stations
with integrated waste-heat recovery.
Thereby cooling air is re-circulated
until it is suitable for heating of build-
ings.
Sawing, marking, packing,
weighing, strapping
After cooling logs are transported to
the saw plant, passing over a combi-
nation of storage conveyors, shuttle
cars, roller table lines etc. Once cut
at the saw, all billets are marked. The
introduction of a pin-stamping unit
in recent years is a small but essen-
tial innovative contribution to full
automation. Prior to that, changing
of hard stamp stencils was the only
remaining operator task. Todays pin
stamping unit receives marking in-
formation directly from the control
system, eliminating time-consuming
manual changing of stencils and po-
tential mistakes by inserting incorrect
numbers.
HE has developed its own pin
stamping unit, as other systems avail-
able on the market were too slow.
Head and butt ends and scrap piec-
es are gripped in sawing position by
a scrap manipulator and deposited in
scrap containers. The manipulator is
designed to also remove sample discs,
which are placed on a dedicated tray
or chute.
Swarf is extracted directly from the
saw and pneumatically transported to
the briquetting press. There swarf bri-
quettes are formed immediately after
sawing, to a density 2.2 to 2.4 kg/dm3.
Such briquettes remelt in a similar
way to ingots, achieving extremely
low melt loss.
Cut billets now travel to the pack-
ing area on roller table lines. The
packing plant shown is designed for
creating long and short billet stacks
simultaneously. This type stacker is
particularly suited for bulk produc-
tion of short billets, when long billet
requirement is limited to say 6.0 m,
whereby 8.0 or 9.0 m is the actual cast
length. This way both casting pit and
homogenising furnace are optimised
for maximum throughput.
Todays standard strapping cen-
tre, also developed by HE, includes
automatic wooden runner magazine
and positioning device. The number
and position of wooden runners and
strapping bands are applied fully au-
tomatically according to customer
specification; no operator interven-
tion or adjustments are required.
Actual strapping is with steel tape, or
more recently with PET-tape. Weigh-
ing of stacks is done prior to and after
strapping, to generate net- and gross
weight.
45
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Ancillary equipment may comprise
label printer and applicator
stack manipulator. (Fig. 6)
The label applicator attaches the label
in a defined position on the bundle.
The manipulator stacks completed
bundles in dedicated positions for re-
moval by fork truck, or stacks directly
onto trailers.
Fig. 6: Sawing and packing
Summary of improvements
Hertwich has achieved numerous
improvements in reliability, compu-
terised control and data collection,
prevention of surface damage, and
furnace control and productivity.
Increase of operational reliability
with extensive, ongoing development,
many improvements were achieved
in recent years. Plants are of sturdy
construction, and of the highest qual-
ity. Plant availability is 99%.
Improved, innovative control
software for operator- and mainte-
nance-friendly production
Fully integrated, automated produc-
tion plants need an excellent control
and monitoring system to ensure safe
and reliable production and high
availability.
Each individual movement of the
plant is monitored for correct execu-
tion.
The refined fault diagnosis sys-
tem efficiently guides operators and
maintenance personnel to the causes
of malfunctions, thereby support-
ing easy and quick corrective action.
Malfunctions are recorded and can be
queried in statistical and trend form,
providing a potent tool to permanent-
ly fix weak points.
Automatic restart programs ef-
46
ficiently and reliably bring the plant
into a predefined condition, eliminat-
ing potential human error.
Log/Billet tracking ensures rel-
evant data on each log or billet is
tracked throughout the system.
Operator-friendly graphic display
of billets within the system includes
all associated data like batch no, di-
ameter, UT-inspection data.
Host connection of the plant
Relevant production data, including
homogenizing parameters, sawing
and stacking dimensions, positioning
of wooden runners, strapping specifi-
cations etc. are downloaded from the
clients production planning and order
procession host system, directly to the
plant control PC. Conversely the plant
PC transmits data to the clients host
system including
measured data of homogenizing (for
quality assurance)
quality inspection results, i.e. centre
cracks, inclusions, surface defects
produced quantities, weights, charge
No., log No., time stamp etc.
Careful handling for improved
billet surface
A new generation of billet supports
with special inlays (patented) has
been developed for the furnaces bil-
let transport system. Thereby surface
damage to billets can be largely elim-
inated. Removal of billets from the
furnace is by a shuttle car, replacing
earlier roller table lines.
Improved heat transfer
More intense hot gas convection and
modified air guide channels have
substantially increased heat transfer
rate to billets without increasing the
number of fans.
HE always prefers to rely on a lim-
ited number a high-quality powerful
ventilators rather than a forest of
ventilators on top of a furnace. This
concept directly results in an air over
temperature (heat head) in the heat-
ing zone of max. 5 to 10 K above the
set metal homogenizing temperature.
Improved direct measurement of
billet temperature inside the furnace
and cooler
Increased production of the furnaces
creates a need for more measuring
points, ever more accurate tempera-
ture control, and for refined data
processing. Consequently direct tem-
perature measurement is now done at
more positions and with higher accur-
ancy. The intelligent analyses soft-
ware with trend analyses provides
an appropriate tool for early recogni-
tion of possible changes to the heating
regime. Implementation provides the
means for even tighter quality con-
trol: Billet diameter and homogeniz-
ing temperature can be changed with
higher safety and great flexibility.
Increased throughput of large
furnaces
The past 10 years has shown a trend
to ever greater throughput of fur-
naces and plants. To date the highest
throughput rate is achieved at Dubal
IV plant, where one billet leaves the
furnace every 82 sec. Throughput is
22 t/hour or 1.050 billets per day.
Conclusion
HE continuous production plants for
extrusion billet have been steadily im-
proved and are therefore fully devel-
oped plants: HE draws from a wealth
of experience, with 80 such plants
built to date, so as to provide tailor
made solutions in terms of functional-
ity and available space.
All HE plants are designed and
built exclusively upon proprietary
know-how by HE itself, including an-
cillary equipment like UT-inspection,
strapping, and swarf briquetting.
20 highly qualified engineers are
available to develop control software
and data management for clients host
systems. Our customers can be sure
of busing a fully developed, top-qual-
ity plant, which ensures reliable pro-
duction throughout an exceptionally
long service life. With HE building and
supplying all components of a plant,
comprehensive after sales and spare
part support is offered.
Author
Dipl.-Ing. Franz Niedermair (1952) is since
1989 with Hertwich Engineering (HE) in
R&D and marketing. Since 1994 he is Man-
aging Director of HE.
ALUMINIUM 1-2/2007
 






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A L U M I N I U M S M E LT I N G I N D U S T R Y

De Nora inert metallic anode: further developments

V. de Nora, T. Nguyen, R. von Kaenel, J. Antille, and L. Klinger, Sierre

A stable inert metallic anode of-

fers many advantages [1,2] and
allows great freedom in choice
of shape. However, an oxygen
evolving anode (OEA) may need
more electrical energy if used in
a conventional way. To minimise
the specific energy consumption,
semi-vertical electrodes were
studied and tested on a laboratory
scale. A semi-vertical configura-
tion helps to maintain the cells
thermal equilibrium even if the in-
terpolar distance is less than 3 cm.
This advantage compensates for
the thermodynamic penalty of the
oxygen evolving anode, and could
double the cells productivity. This
paper establishes the thermo-elec-
tric conditions of the cell having
a semi-vertical configuration of
the oxygen evolving anode, and
presents the experimental results
of the semi-vertical electrode con- Fig. 1: de Nora inert metallic an-
odes used to operate between
figuration in a 100 A laboratory
100 A to 300 A per anode in labo-
cell. ratory cells

For several years Moltech studied and

developed an OEA for the aluminium
reduction cell; some examples of lab-
oratory cells of de Nora Inert Metallic
Anodes are shown in Fig. 1. The ret-
rofitting of the de Nora inert metallic
anode in commercial cells has been
demonstrated in a pilot cell of 25 kA
[1] using larger anodes (Fig. 2). De-
spite the low oxygen over-potential of
the cobalt oxide based active coating,
the OEA still presents a penalty of 650
mV [2]. This penalty must be compen- Fig. 2: Pilot de Nora inert metallic
anodes used to operate between
sated by increasing the anode current
3500 to 4500 A per anode.
density (horizontal configuration) or
by increasing the anode surfaces with
a semi-vertical configuration.
Table 1: Characteristics of the de Nora inert metallic anode

De Nora inert metallic anode

The de Nora inert metallic anode
consists of a metallic substrate made
of cast Ni-Fe-Cu alloy; the external
surfaces of the anode are protected
by an active coating of CoxNiyO, with
0.65 < x < 0.85 and 0.15 < y < 0.35.
Table 1 summarises the anode char-
Metal substrate resistivity (:.m) 3.10-7
Oxide coating resistivity (:.m) 3.10-2
Oxygen activation over-potential (V) 0.10
Experimental oxidation rate of metal substrate (m/year) 1.8 10-3
Linear dimension change (m/year) - 2.0 10-3
Expected life time (years) 1 - 1.5

48 ALUMINIUM 1-2/2007
SPECIAL
acteristics and performance tests in
horizontal configuration, described
previously [2].
The anode metallic structure is fab-
ricated by a sand casting technique,
which can be adapted to every size
and form of the anode. This advan-
tage is valuable for adapting to non-
horizontal configurations. In fact, the
shapes of the anode and active runner
need to respect the:
current distribution
gas escape direction
hydrodynamic effects of the
gas-liquid energy transfer assuring
the bath circulation.
Non-horizontal electrode
configuration
Test description
Several configurations of the non-
horizontal electrode assembly were
designed and tested in 100 A labora-
tory cells. The selected electrode ma-
terials were the following:
cathode: semi-graphitised BN car-
bon substrate, totally covered by 1.2
mm of Tinor 2000 coating. The coat-
ing was pre-aluminised by 3 layers of
aluminium slurry in basic colloid as
shown in Fig. 3.
anode: Ni-Fe-Cu alloy substrate
made by sand casting, and totally
covered by 250 Pm of Co-Ni electro-
deposition. The oxide active coating
was obtained by pre-oxidation in
air at 950 C. The coated anode was
cooled down to room temperature be-
fore use.
The 100 A laboratory cell is exter-
nally heated by an electrical furnace.
A graphite crucible having an internal
Fig. 3: Semi-vertical cathode before and after aluminisation
49
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
square section of 180 x 180 mm and
300 mm height is used as the elec-
trolysis cell. The graphite crucible is
protected by an Inconel 600 pot, with
a cast alumina sleeve on the top.
Depending on the operational
mode, the crucible can be used as the
cathode current feeder through the
electrical connection by the Inconel
pot. The vertical side walls of the
crucible are protected and insulated
electrically by four alumina sheets of
15 mm thickness. The cell set-up is
placed in an electrical furnace, which
controls and maintains constant the
operating temperature.
The electrolysis tests are per-
formed in a bath of 11% AlF3 excess
4% CaF2 7% KF 9% Al2O3 (satu- corresponds to the formation and de-
ration), at 930 +/- 5 C. The cathode
and anode current densities are iden-
tical and maintained constant at 1
A/cm2.
Vertical assembly with
hanging cathode
In the vertical configuration the in-
clination of the electrodes is 0, the
assembly is composed of one cen-
tral cathode and two parallel anodes
as illustrated in Fig. 4. The cathode
electrical connection is through an
external stem made of steel core in-
serted inside a copper tube of 2 mm
wall thickness. Two similar stems are
also used for the two anodes; the three
horizontal active runners of the anode
are inclined with a slope of 10 to the
vertical, so allowing the gas to escape
along the anode back. The anode-
cathode distance is fixed at 2 cm.
The advantages of the hanging
cathode assembly are:
compact arrangement of the elec-
trode assembly; the total active sur-
faces can be increased by a factor of 2
compared to the horizontal surface
movable cathodes which can be
changed at the end of the coating life-
time
no vertical polarisation interference
with the metal pool stored on the cell
bottom.
Experimental results
The cell operates at a very stable volt-
age of 4.0 0.1 volts; the wettability
and the draining operation of the
cathode can be observed by the saw
tooth profile of the cell voltage, which
tachment of the aluminium drop at
the cathode bottom.
After 500 hours (more than 20 days)
the test had to be shut down because
All photos: Kannak
Fig. 4: Vertical assembly with Tinor coated
hanging cathode
of deterioration of the alumina side
wall protection, and because of cor-
rosion of the cathode stem by liquid
aluminium. The cathode and anodes
were removed for examination:
The anodes were slightly corroded
at the back and at the lower runner.
This local corrosion is due to chemi-
cal interaction with carbon dust (from
the crucible) and with the metal pool
stored on the cell bottom.
The cathode remained intact, and
totally covered by a layer of alumini-
um of 2 to 3 mm.
Discussion
As expected, the fundamental behav-
iour of the de Nora inert metallic an-
ode is not influenced by the vertical
position. However the observations
during the test make it possible to
point out the following aspects of the
49
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
vertical configuration:
The initial current efficiency of
75% decreases rapidly, and stabilises
at about 40% after 24 hours.
The oxygen separation, in escaping
along the anode back, is not optimal
in the vertical position, namely with
an ACD as low as 2 cm. The re-oxida-
tion of the metal by oxygen seems to
be one of the factors decreasing the
current efficiency.
The aluminium pool stored on the
cell bottom is subjected to the positive
electrical field of the anodes (poten-
tial of + 0.3 volt versus the cathode);
an electrochemical dissolution of the
metal can occur probably further de-
creases the current efficiency.
Semi-vertical electrode
configuration
To improve the gas separation, a
semi-vertical electrode assembly
was designed and tested. The active
surfaces of the cathode and the an-
ode are inclined with a slope of 40.
The cathode is one semi-graphitised
block having adequate active surface
geometry; the cathode is glued on the
graphite crucible bottom and totally
covered with 1.2 mm of Tinor 2000
coating; the coating is pre-aluminised
by aluminium slurry. The cathode
electrical connection is made via the
crucible and an aluminium pool of
about 4 to 6 cm on the bottom. An
inclined anode presents three hori-
zontal runners with a flat active face
parallel to the cathode surface; to
minimise the vertical polarisation the
lower runner is kept at least 4 cm from
the metal pool on the crucible bottom.
The cathode-anode distance is fixed
at 2 cm (see Fig. 5).
The advantages of the semi-verti-
cal configuration are:
better gas separation minimises the
metal re-oxidation by oxygen
no external stem needed for the
electrical connection of the cathode
cathodic protection of the metal
pool stored on the crucible bottom
suppresses its electrochemical disso-
lution.
However, this assembly is less
compact than in the previous one;
the maximum surface increase factor
is about 1.5. The cathode is not mov-
50
able, thus it cannot be changed during
operation.
Experimental results
The cell operates at a very stable volt-
age of 3.8 0.1 volts; in comparison to
the previous case the saving of 0.2 volt
should be due to the lower ohmic drop
of the cathode body and connection.
Fig. 5: Semi-vertical cathode-anode assembly
The visual observations during opera-
tion show that the gas separation is
greatly improved by the inclination of
the anode; and because the metal pool
is protected by the cathodic polarisa-
tion, the current efficiency stabilises
at about 70 to 75%. At a minimum
distance of 4 cm between the lower
runner of the anode and the metal
pool level, the vertical polarisation is
less than 10%, estimated by measur-
ing the variation of the cell voltage in
raising the anode position. After 500
hours of operation the anode is intact
(Fig. 6), and the cathode active surface
remains clean, without any sludge de-
posit or dimensional change.
Discussion
The gas separation is a major pa-
rameter in current efficiency; as the
better results with the semi-vertical
electrode assembly clearly demon-
strate. The angle of inclination can be
optimised in taking into account the
gas hydrodynamic, the compactness
of the assembly, and the runner form
for the current distribution.
Thanks to the wettability of Tinor
coating, a good cathode electrical
feeding through the liquid metal
pool should induce only a very mar-
ginal ohmic resistance. The concept
of an immersed cathode must be
developed so that the cathode can
be removed at the end of the Tinor
coating life-time. Fig. 6 shows an in-
clined metallic anode after 500 hours
of operation.
ACD in semi-vertical
configuration
A numerical study of the semi-vertical
configuration has been made in order
to investigate the current density dis-
tribution and the impact on the cur-
Fig. 6: Inclined anode after 500 hours of
operation
rent density of a slight mis-alignment
of the electrodes.
The first experimental setups
showed oscillations in the voltage.
Although the cause was eventually
shown to be related to an insufficient
bath level (causing too large a thermal
volatility), it was first thought that the
cause might be a difference in the
current carried by each of the three
horizontal runners. Indeed, when the
mean current density is above 1.3 A/
cm2, this leads to voltage oscillations.
The theoretical model, a plain elec-
trostatic computation of the electrical
potential and current density, showed
that in the nominal configuration,
there is a difference in the amount of
current carried by each runner, but
the difference is too low to explain
the oscillations. There is, however, an
interesting point to be made by elec-
trostatic modelling, as follows.
Fig. 7 is a typical result for the se-
mi-vertical configuration. Along with
the anode (top) and cathode (bot-
ALUMINIUM 1-2/2007
 

















 






 


  

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A L U M I N I U M S M E LT I N G I N D U S T R Y
tom), a surface of constant potential
is shown (middle). It explains why
more current is carried by the lower
runner. Because the current density
is proportional to the gradient of the
electrical potential, it follows that
regions where the isosurface of the
potential are curved, a large current
density results.
Two main conclusions can be
drawn from such electrostatic mod-
elling:
In order to obtain a more homo-
geneous distribution of the current
density, one should purposely set the
anode in a non-parallel position rela-
tive to the cathode, and specifically by
having a slightly lower ACD under the
top runner.
In a future semi-vertical design
gathering many anodes, it will be
necessary to perform electrostatic
simulations of this kind to optimise
the arrangement and setting of the
electrodes, in order to smooth the
current density distribution as far as
possible.
Fig. 7: Semi-vertical electrodes setting, and
an isosurface of the electrical potential.
We recall that optimising the current
density distribution in the above-
mentioned sense is important for de
Nora inert metallic anodes, because,
on the one hand, they require higher
current densities (thermal equilib-
rium, see below), while, on the other
hand, a critical current density exists,
above which the anode may be dam-
aged. Thus, a good inert anode design
ensures an even, high current density
distribution. In fact an even current
distribution is also very important in
52
horizontal conventional industrial
cells. If the anode current densities
are too different, large horizontal cur-
rent take place in the liquid metal that
may lead to metal pad wave oscilla-
tions. If the cathode current density
is too uneven, large local electro-ero-
sion may take place, leading to short
cell lifetime.
Energy considerations
As has been noted before [7], one of
the problems to address to bring the
oxygen-evolving anode to industri-
alisation is the thermal balance of the
cell. About 1 V of the total cell voltage
is used differently in each technology:
as heat for the classical Hall-Hroult
cell, and to produce aluminium in the
OEA cell. From the point of view of
energy efficiency, this is very positive
for cells implementing the de Nora
inert metallic anode, but the corre-
sponding loss in heating is significant
and means that a balanced thermal
design is difficult to achieve.
Let us consider the problem in-
versely: assume that we want to op-
erate an oxygen-evolving anode that
has
a. the same current efficiency
b. the same specific energy
c. and the same heat losses
as a conventional cell; how do these
conditions translate into operat-
ing parameters? The first condition
should be relatively easy to meet,
since Moltech could operate a 25
kA OEA cell with 90% CE [1], while
struggling against various operational
difficulties that are to be expected in
such novel tests. We thus assume that
the current efficiency is the same for
both technologies, K= 0.95.
The second condition, when the
first is met, consists in having the
same cell voltage in both technolo-
gies. To work out the third condition,
we recall that the heat generation loss
Q is given by ([8], respectively with
only D alumina and no Boudouard
reaction):
Qc = Ic (U 1.65 K 0.48)
Qm = Im (U 3.11 K)
Where the c subscript designates
carbon or conventional technology,
m standing for metallic (anodes). I is
the current, U the cell voltage and K
the fractional current efficiency. The
third condition, Qc = Qm, is in fact a
condition on the current. For typical
designs, we get Im = 1.7 Ic. Is it possible
to meet both the voltage and current
conditions?
The electrode settings studied in
this paper address the conditions
above. Let us consider only the semi-
vertical configuration, since it is more
efficient. The cell voltage condition
can be met by decreasing the ACD, to
overcome the voltage penalty of the
oxygen-evolving anode. When taking
both the reversible decomposition
voltage and the over-voltages of the
various electrodes into account, it is
commonly assumed to be about 0.6 V
[1,2]. For typical electrolyte conduc-
tivities used in our tests, it amounts to
a reduction in ACD of about 1 to 2 cm.
Thus, operating a semi-vertical con-
figuration at 2 cm ACD makes it pos-
sible to meet the voltage condition.
Finally, to meet the condition on
the current, for a similar overall cell
size, the semi-vertical setting offers
a two-fold gain: by using a de Nora
inert metallic anode, one can work at
higher current densities (by a factor
of 1.4), while using slanted de Nora
anodes permits an increase in the
working area (thus the total current)
by a factor of at least 1.5. Thus, expect-
ing a total current Im = 2.1 Ic appears
realistic. The 1.4 factor is explained by
the typical current density in conven-
tional technology (0.9 A/cm2), com-
pared to the maximal current density
for metallic anodes (1.3 A/cm2). The
second factor is geometrical. For the
setting presented above, the cathode
surface is 100 cm2, and only the flat
surface of the runners is about 55
cm2. However, while exact quantifi-
cation is difficult, the active surface of
the anode is more than the flat area.
For conventional designs, a horizontal
cathode occupying the same overall
space has a surface of 50 cm2. Thus,
a 1.5 geometric factor appears reason-
able, and implies a more compact cell
for the same productivity
Conclusions
The gains of energy and production of
the aluminium reduction cell in using
the semi-vertical electrode configura-
ALUMINIUM 1-2/2007
SPECIAL
tion are demonstrated by our prelimi-
nary simulation calculations:
The thermodynamic penalty of the
oxygen evolving anode is largely com-
pensated by decreasing the ACD.
The cell thermal balance can be
maintained by higher current thanks
to a significant increase of the operat-
ing surface area.
The preliminary tests in laboratory
100 A cells have demonstrated that:
the de Nora inert metallic anode
and the Tinor coated carbon cathode
can be used as dimensionally stable
electrodes for the non-horizontal
electrode configuration. However,
the dimension stability of the car-
bon cathode was only proven for 500
hours. This dimensional stability is
still in question for longer duration.
Aluminium casting
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applications extending from packag-
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loyed with various metals, such as
magnesium or silicon in extruded pro-
files, its strength can rival that of steel.
Obtained by an electrochemical proc-
ess, the metal occurs in aluminium
53
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
the metallic inert anode and the
wettable Tinor coated cathode can
operate at an ACD as low as 2 cm.
the gas separation is an important
factor influencing the current effi-
ciency, which can be optimised by
appropriate anode design.
the design freedom of metallic
anodes is unique, and constitutes an
important advantage for the non-hori-
zontal electrode configuration.
References
[1] J. Antille et al.: Light Metals 2006,
pp. 391-396
[2] T. Nguyen and V. de. Nora.:
Light Metals 2006, pp. 385-390
[3] V. de Nora: Electrochemical Soc.
Interface - Winter 2002, pp 20-24.
[4] J.N. Bruggeman et al: Wettable
foundries and smelting works as a liq-
uid at a temperature of around 700C.
Since this melt is very aggressive, the
contacting surfaces must be protect-
ed. That is first to counteract wear of
the tools and vessels and, second, to
prevent the aluminium from being
contaminated with dissolved foreign
matter. That means specifically the
launders in casthouse applications as
well as crucibles, ladles and dies used
in foundries. The surfaces that come
into contact with the molten alumin-
ium must be coated to prevent cor-
rosion. The quality of these surfaces
not only determines the lifetimes of
the equipment and tools used, but also
has a critical effect on the quality and
mechanical and physical properties of
the resulting castings.
A typical example is the transport
of molten aluminium in cast houses,
which is usually performed in laun-
ders with a refractory lining. Of course,
such launders have poor thermal con-
ductivity, which prevents rapid cool-
ing of the melt. However, a thin oxide
ceramic based drained cathode
technology for aluminium reduction
cells US DOE DE-FC07-97 / ID /
13567 Dec. 2002, pp 1-42
[5] Huimin Lu et al.: Light Metals 2006,
pp. 687-690
[6] H.A. Oye et al.: Light Metals 1997,
p. 279-286
[7] V. de Nora: Proceedings 11th
Intern. Aluminium Symposium;
Trondheim Bergen Trondheim;
Sept. 2001, pp 155-160
[7] H. Kvande: Light Metals 1999,
pp. 369-376
[8] W. Haupin and H. Kvande:
Light Metals 2000, pp. 379-384
Authors
Vittorio de Nora, Thin Nguyen and Rene
von Kaenel are with Moltech Technology
Center, while Jacques Antille and Laurent
Klinger are with KANNAK S.A.
skin rapidly forms on the surface of
the hot aluminium. A release agent
must be added to prevent this skin
sticking to the surface. Traditionally,
bone ash is added, which does indeed
have the required release properties
but because of its poor adhesion must
be repeatedly replenished, since it is
entrained by the flowing molten
aluminium.
Boron nitride versus bone ash
Ceramic coatings offer an alternative
to bone ash. These foundry coatings,
which are applied as liquids and dry
to form a solid film, should have high
thermal and chemical stability and a
similar thermal expansion to the coat-
ed surface in order to prevent the coat-
ing flaking off. A material that ideally
meets all these requirements is boron
nitride (BN). The graphite-like chemi-
cal structure of BN makes it an ideal
release agent and lubricant. However,
unlike graphite, which oxidizes at
above 500C in air, boron nitride is
53
ALUMINIUM 1-2/2007
 A L U M I N I U M S M E LT I N G I N D U S T R Y
All photos: ESK
Casting table for aluminum billet production coated with
EKamold Cast-C prior to use
Casting table for aluminum billet production coated with
EKamold Cast-C after use
SEM picture of a cross section of EKamold Cast-C Coating
characterized by a high thermal sta-
bility that allows it to be processed
up to over 900C. That makes boron
nitride completely thermally stable in
the temperature range used for light-
metal casting.
A property that is particularly at-
tractive for casting is the poor wetta-
bility of its surface by liquid alumin-
ium and other molten metals. They
do not stick to the smooth surface
but roll off like water droplets from a
lotus leaf. The wetting of ceramics by
melts is usually described by means of
the wetting angle. The contact angle
54
of a melt droplet on the substrate is
measured by forming a tangent. Large
angles over 90 mean poor wetting,
while small angles less than 90 indi-
cate good wetting. At a temperature
of 900C, boron nitride has a wetting
angle of 160, which corresponds to
poor wetting.
However, this welcome property
also has a downside, since the poor
wetting of the BN platelets also im-
pairs their adhesion to the substrates
to be coated, such as ceramic laun-
ders, ladles, crucibles, dies or metal
moulds. To improve adhesion, there-
fore, a refractory binder must be used.
In the coatings, these binders bond
the BN particles together as well as
to the substrate. In the past, phyllo-
silicates, monoaluminium phosphate
and magnesium silicate have been the
chief refractory binders.
High adhesion thanks to nano-
particles
The binders that have been commer-
cially available so far are not ideal for
the casting industry, says Christiane
Klpfer of the technical marketing
department at ESK. A major disad-
vantage is that they are only suitable
for applying thin coatings, since oth-
erwise the rapid temperature cycles
could cause them to flake off. In
looking for improved high-tempera-
ture binders, we hit on sol-gel systems
reinforced with nanoscale particles,
explains Klpfer.
The patented binder system, as a
BN coating for the casting industry, is
called EKamold Cast-C, and is a real
innovation for high-temperature ap-
plications. The system develops its ef-
fect in situ when heat treated during
the first casting cycle, similar to two-
pack adhesives, and forms a film that
is resistant to both heat and abrasion.
Compared to conventional boron ni-
tride-based coatings, this product in-
novation offers unrivalled durability
together with ease of application and
extremely low requirements on the
substrate.
Coatings can be repaired
There are also processing advantages
to using boron nitride (BN). For ex-
ample, BN coatings can be applied
by spraying, brushing or dipping.
Although BN coatings develop their
protective effect at a few microns
thickness, the new BN foundry coat-
ings from ESK can be applied in
thicknesses up to 1 mm. That means
the coating can be readily applied by
untrained staff. The new coating can
be used wherever liquid aluminium is
processed. The range of applications
extends from compact aluminium
ingots to aluminium car wheels and
engine blocks.
Furthermore, the new BN coatings
developed by ESK, for the first time
ever, allow damaged coatings and
cracks in the substrate to be repaired.
In the traditional process, if the coat-
ings were damaged, they had to be
painstakingly removed and then reap-
plied. With the new systems, damaged
areas of the coating can be repaired
e.g. with a brush. Moreover, the
coatings can seal cracks and chipping
in the substrate by infiltrating them.
No sedimentation thanks to
thixotropy
Traditional BN coatings generally
had the problem of sedimentation of
the BN solid particles, and had to be
very carefully stirred to prevent set-
tling out, which would change the
properties. The new ESK coating
offers a further advantage, since, al-
though it becomes gel-like after stand-
ing for a long time, it can be easily liq-
uefied again by stirring or shaking a
property known as thixotropy. All
these completely new possibilities
offer major advantages to users, en-
thuses Thomas Jngling, Chief Tech-
nology Officer of the California-based
Ceradyne Inc. Cast houses and foun-
dries are harsh environments, where
users must be able to depend on the
materials used operating flawlessly.
The casting industry is very interest-
ed in the new boron nitride coatings,
observes Jngling. The new coatings
have already been subjected to practi-
cal tests in aluminium foundries.
Boron nitride coatings last longer
Guido Heuts of the Dutch company
Ceranex, a supplier of heat-resistant
ALUMINIUM 1-2/2007
SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y

Why Boron nitride has similar properties to graphite

Boron nitride, a synthetic substance with the
chemical formula BN, is a sort of inorganic
carbon. That means BNs chemical and
physical properties are very similar to those
of graphite, since both compounds crystal-
lize with the same layer lattice and almost
identical dimensions. Two adjacent carbon
atoms of the graphite lattice can therefore
be substituted with a nitrogen and a boron
atom, since two carbon atoms together
have exactly the same number of electrons
as a boron-nitrogen pair. Accordingly, graph-
ite and BN are isosteric, which, as with other
isosteric pairs, such as nitrogen and carbon
monoxide or nitrous oxide and carbon
dioxide, is manifested as a striking physical
and chemical similarity. For example, at tem-
peratures of around 1600C and pressures
of 50,000 bar, graphite-like -BN can, in a
similar way to carbon, be transformed into 2
diamond-like cubic high-pressure allotropes
with similar hardness to diamond. However,
the striking difference between graphite and
BN is that the latter is white and does not
conduct electricity. That is because BN, un-
like graphite, does not possess any mobile -
electrons, since, because the member atoms
of the lattice are dissimilar, the excess elec-
trons remain fixed to the nitrogen as lone
electron pairs. However, more important for
the application in the aluminium industry is
the resistance against oxidation up to 900C
compared to graphite which will start to oxi-
dize already at 500C. In its most widespread
form, as a graphite-like hexagonal boron
nitride, the snow-white material possesses
exceptional thermal and chemical resistance.
At the same time, the highly thermally
conductive material but electrically insulating
boron nitride also has good lubricity. This
unique combination opens up a wide field
of applications in which the material often
provides the critical enhancement to high-
end products. Some would not be possible
at all without boron nitride. In this manner,
the range of applications extends from elec-
trical insulation in high-temperature furnaces
to applications in the cosmetics industry.

and chemically resistant materials for
manufacturing industry, emphasizes
the high abrasion resistance of the
new BN coatings. Heuts is responsi-
ble for the aluminium industry divi-
sion in his company and understands
the particular challenges faced by this
sector. Traditional coatings were al-
ways entrained by the flowing molten
aluminium. But the new product ad-
heres much better and does not have
to be reapplied as often, he explains.
The coatings have much longer life-
times if the liquid aluminium does not
have a chance to attack the substrate.
This could greatly reduce downtimes.
The bottom line for aluminium proc-
essors is significant boost in efficiency
as a result of time savings and higher
productivity. The improvement is
documented by the results of the qual-
ity control. With the BN coatings we
tested, in contrast to traditional ma-
terials such as bone ash, the castings
did not contain any residues, Heuts
assures.
ievable elasticity to the coatings. The
coatings have a levelling effect since,
within certain limits, they adapt to
their environment and can expand
and shrink without suffering damage,
explains Christiane Klpfer.
The flexibility also applies to the
adhesion of the binder to the substrate
to be coated, which may be smooth or
porous. We were even able to make
boron nitride adhere to graphite,
Klpfer says. This additional proper-
ty is important for graphite parts that
are used in aluminium cast houses
and foundries. They include rotors
for melt degassing or boron nitride-
coated graphite thermocouple tubes.
Other additives are under develop-
ment. Boron nitride has high thermal
conductivity. That is counterproduc-
tive for aluminium production, con-
tinues Klpfer. For example, liquid
aluminium cools by about 1C per
second on average when conveyed
with ladles. This heat loss has to be
compensated by auxiliary heating.
ESK is currently working on BN coat-
ings precisely tailored to the needs
of the aluminium-processing indus-
try. The aim of this work is to find a
further additive that will allow us to
market a boron nitride with reduced
thermal conductivity.
Authors
Christiane Klpfer, ESK Ceramics GmbH
& Co. KG, Germany.
Dr. Thomas Jngling, Ceradyne, Inc., USA.
Guido Heuts, Ceranex B.V., Netherlands.

and they are flexible Platzhalter fr die

redigitalisierte Anzeige Padelttherm
Besides their high mechanical stabil- 90x63 mm, sw, Motiv: Industrieofen
ity, the new BN coatings are also char-
acterized by high flexibility. To rec-
oncile apparently contradictory ma- Original-Datei:
terial properties, a third component Padeltherm_Metall_11_03.EPS
was incorporated into BN coatings
besides the binder. This innovation,
which has also been patented, is an
additive that imparts hitherto unach-

55
ALUMINIUM 1-2/2007 55
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Thyristor rectifiers for aluminium plants
with advanced free-wheeling control
S. Tambe, W. M. Lauwrens, M. Rechsteiner, Turgi
Potline current demand for alu-
minium plants is constantly in-
creasing. Many potlines with 350
kA are in operation, and the trend
is towards 500 kA in the near fu-
ture. Such requirements call for
many rectifier units in parallel.
Due to physical limitations on the
size of a rectifier, as well as to re-
dundancy requirements for safety,
using many units in parallel poses
a great problem of how to handle
current stoppage when all units
are tripped simultaneously. Due
to staggered switching-off times of
the rectifiers, it is likely that the
last unit will briefly carry the full
potline current. In a diode plant
this phenomenon can be handled
easily, as all diodes go into a natu-
ral free-wheeling mode. Thyristor
plants by contrast, require imple-
menting a special technique to
prevent destructive overloading of
the last switched unit. ABB has de-
veloped an advanced technique to
handle such phenomena without
over-dimensioning any unit.
Continuity and reliability of DC pow-
er supply are the basic requirements
for aluminium smelters, together
with safety. In the past, diode recti-
fiers were the natural choice due to
their simplicity. However, tap-chang-
er maintenance was always an issue
for maintenance people, and control
speed is another drawback.
With the availability of reliable thy-
ristors and digital firing circuits, users
All illustrations: ABB
also started selecting thyristor recti-
fiers for smelting aluminium. These
rectifiers need less maintenance and
have higher efficiency. Though nor-
mal operation with thyristor rectifiers
was simple to handle, potline trip was
a serious concern. This is due to the
fact that the last fired thyristor pair
will take the load of the full potline
current. This led to overloading of the
last switched rectifier. In case of diode
plants, the complete bridge acts like a
56
free-wheeling circuit. But with thyris-
tor rectifiers, the last pair of conduct-
ing thyristors suffers overload. A spe-
cial technique was necessary to avoid
overload damage.
This paper discusses the new tech-
nique implemented by ABB to avoid
overloading of any pair of conduct-
ing thyristors. The advantage of this
technique is that algorithms are im-
plemented for each unit, and hence
the design of all rectifier units remains
identical in power and controls cir-
cuits. This paper also describes how
overloads relate to potline circuit
behaviour and process, and to other
sources of overload.
This paper covers the following ar-
eas: process characteristics, minimis-
ing the risk with advanced control,
results and conclusion.
Process characteristics
A typical equivalent circuit diagram
of an aluminium smelter application
can be represented as follows:
The rectifiers connected in parallel
Fig. 1: Equivalent circuit diagram of an aluminium pot- time. Another reason why
line with parallel feeding thyristor rectifier plant
deliver the required total process cur-
rent. This current is called as potline
current (Idc-PL).
The considerable busbar length of
more than 1000 meters, and cross
section of 200300,000 mm2, results
in a process time constant W (= L/R)
of about | 250 ms, where L is busbar
inductance and R busbar resistance.
This means the potline current will
require at least a second (4 x W = 1000
ms) to decrease from its rated value to
practically zero.
Rectifier behaviour under tripping
modes:
Normal mode: Unlike diode rectifier
units, thyristor rectifier units have a
faster response time and are fully con-
trollable. But it is a fact that a thyris-
tor rectifier cannot cutoff the current
once it has been triggered. In rectifier
operation thyristors are line commu-
tated. This inherent characteristic of
each individual unit, together with
the phase shift between various other
parallel feeding units, corresponds to
the asynchronous behaviour of each
rectifier unit, functioning in turn.
During operation each unit can be
switched off manually or automati-
cally tripped by abnormal operating
conditions, such as overtemperatures,
loss of cooling medium, etc.
As long as only one unit goes
out of service, this does not
pose a serious threat to con-
tinuous potline operation.
Potline trip mode: However,
there are certain conditions
under which it becomes
necessary to trip all units
simultaneously. This is
known as potline trip. On
initiation of a potline trip
command, the rectifiers can-
not all switch their current
to zero at exactly the same
the potline current cannot
be interrupted instantly is
because of the large circuit reactance
associated with the energy stored in
its large magnetic field. Assuming the
current remains constant during this
brief switching period, the last unit to
ALUMINIUM 1-2/2007
SPECIAL
switch off has to carry the total potline
current. In this undesirable situation,
this unit consists of only two legs, one
positive group and one negative group
of one rectifier.
To prevent these thyristors from
overload requires forcing conduction
in all thyristors from positive and neg-
ative groups of all the rectifier units.
This conduction mode, when the en-
ergy driving current flow is circuit in-
ductance, is called free-wheeling.
Minimising the risk with
advanced control
A potline trip as described above will
lead to lead thyristor failures, if no
remedial measures are taken. Exces-
sive current may cause major damage
to the rectifier as a whole. ABB has
developed special control and firing
techniques to handle such trips. Some
of the abnormal and high risk condi-
tions for rectifiers are:
Hardware trip of all units, such as
an emergency stop
57
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Network under-voltages leading
to trips
Loss of total network
Process trip.
In order to prevent the damage to cer-
tain thyristors as mentioned above, it
is essential to share the free-wheeling
current among all units and all semi-
conductors. The duration of this, free-
wheeling mode could be of the order
of one second to evacuate reactance
energy. In a 50 Hz, six pulse system,
the firing angle is updated every 3.3
milliseconds. The advance control
Fig. 2: Mode 1
which controls the free-wheeling re-
placed this by a different mode.
Firing mode on a single unit (Fig. 2):
As soon as the control system senses
a fast hardware trip (trip due to un-
der-voltage or loss of network) then,
on the next firing instant it fires all
thyristors coloured red in all units. At
the same time it initiates an off com-
mand to all the breakers. As soon as
the control system from a particular
unit receives back signalization that
its breaker is open, then it initiates the
next action as mode 2 shown in Fig. 3.
As soon as a control system receives
Fig. 3: Mode 2
57
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y

a feedback signal that a main breaker and

filter breaker (if installed) are open, then it
fires all thyristors in that unit. All units be-
haviour: Mode 1 can be implemented in all
units. But as all units are not synchronised in
firing, they come to mode 1 independently of
each other. Fig. 4 shows when all units are
in mode 1.
Fig. 4: Mode 1 This technique shares the current among all
units so that no single arm gets overloaded.
It thereby dissipates potline energy safely.
When all breakers are open, all units come to
mode 2 as shown in Fig. 5.
It should be noted that all units do not
shift from mode 1 to mode 2 simultaneously.
Switching occurs depending upon breaker
opening instant. This logic, which is imple-
mented in each unit control software, needs
Fig. 5: Mode 2 fast information about a trip. This is imple-
mented as shown on Fig. 6. This technique brings all units and
all thyristors into free-wheeling mode with minimal time dif-
ference between the units.

Results and conclusion

This advance technique was implemented on an aluminium

Fig. 6: Fast links for hardware trips and controls
plant and was tested under different modes of tripping. Fig.
7 shows typical overloading current of the thyristors during
a trip condition. Fig. 8 shows that thanks to the free-wheeling
technique, overloading of the thyristors was prevented. The
advanced and proven technique developed by ABB for thyr-
istor plants ensures safety of thyristor plants for electrolysis
applications under the most severe conditions.

Authors

Shripad Tambe, Master of Technology, IIT Kanpur, started in 1977 with

HBB, India. In HBB India he was Senior Research and Development
Manager. Since 1986 he has been working with ABB Switzerland, and
up to 1999 worked in various technical departments including sys-
tem engineering. He is the inventor of two patents registered in many
countries in the area of rectifiers for DC arc furnaces. From October
1999 to 2005 he has been worldwide responsible for retrofit, revamp
and upgrades of rectifier plants for electrolysis and arc furnaces. He is
DGM, Systems Group and head of sales and projects ABB Switzerland
Ltd. Service Division and is presently DGM for large projects and is
responsible for rectifier systems for aluminium and DC arc furnaces.
Fig. 7

Wynand M Lauwrens gained a Bachelor of Engineering in South Af-

rica. He joined ABB South Africa in 1994 and was responsible for
engineering and commissioning drives and rectifiers control systems.
He joined ABB Switzerland in 2002 as control engineer in the HPR
Division, and is responsible for engineering and commissioning recti-
fier control systems.

Markus Rechsteiner gained a Bachelor of Engineering at ITR Rapper-

swil Switzerland. He joined ABB in 1997 as Project- and Commis-
sioning engineer. From October 2001 to 2005 he acted as sales and
project manager in the HPR Service Division. Presently he is responsi-
ble for marketing and communication in the ABB High Power Rectifier
group.
Fig. 8

58 ALUMINIUM 1-2/2007
SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y

Moeller direct pot feeding technology

T. Letz and C. Duwe, Pinneberg

Since September 2001 the Moeller

direct pot feeding system for the
smelter plant Aluminij Mostar in
Bosnia-Herzegovina has been in
successful operation. VAW Alumi-
nium Technology chose Moeller in
July 2000 to modify 256 alumini-
um smelting pots (4 potlines with
64 cells each).

The Moeller direct pot feeding for

Aluminij Mostar employs dense phase
conveying via pressure vessel and
Moeller turbuflow conveying pipe to

All illustrations: Moeller

take the secondary alumina from the
storage silo to intermediate bins near
the pots and combines this with the
Moeller fluidflow air slide pipe within
the pots. A schematic presentation
of the system installed in Mostar is Fig. 1: Direct pot feeding side-by-side (Mostar, Bosnia-Herzegovina)
shown in Fig. 1.
The (single-)pressure vessel sys- pneumatic conveying system for section of pots. The pressure vessel
tem is a non-continuously working feeding secondary alumina to one (2) for the dense phase conveying to

59
ALUMINIUM 1-2/2007 59
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
Fig. 2: Direct pot feeding with Moeller Fluidflow
the intermediate bin (5) is equipped
with a Moeller filling valve, a Moel-
ler conveying pipe shut-off valve and
the necessary pneumatic valves, ball
valves, non-return valves, etc. for the
optimal fluidising and conveying air
distribution of the alumina. The fluid-
ising and conveying air is supplied by
a separate compressor (8) or the plant
net. The secondary alumina, generally
from the secondary alumina silo of the
fume treatment plant (FTP), is con-
veyed via the turbuflow conveying
pipe (3) to intermediate bins (5).
The intermediate bin (5) is the in-
terface to the fluidflow air slide pipe
and is equipped with a filling valve,
air slides at the outlet and level indi-
cators. The intermediate bins (5) start
to fill at a minimum level indication
or after a precisely defined period of
time. The fluidflow air slide pipe con-
nects the intermediate bin (5) with the
ore bunkers of the pots (7) and pro-
vides a continuous supply of second-
ary alumina. Compressed air (8) for
the fluidising air of the fluidflow air
slide pipe comes either from the plant
net for or from a separate blower.
The supply of secondary alumina
to the ore bunkers of the pots (7) is
self-regulating. For safety reasons, the
fluidflow air slide pipe of each pot is
equipped with the 2 m long Moeller
insulation air slide pipe. This equip-
ment does not directly influence the
conveying process, but is a key com-
ponent.
Experiences at Aluminij Mostar
The Moeller direct pot feeding (MDPF)
system has been working with 100%
60
reliability at the smelter plant Alumin-
ij Mostar in Bosnia-Herzegovina since
September 2001. It has maintained
without any problem conveying a ca-
pacity of about 10 t/h over around 150
m for each of the 4 sections (64 cells
each). Furthermore, it has fulfilled all
environmental aspects, especially the
limits on dust emission has been ful-
filled. The MDPF system works abso-
lutely dust free. It has generated no
measurable fines (attrition) or segre-
gation in the last five years.
The maintenance costs for the
MDPF system at Aluminij Mostar are
extremely low. The Moeller turbuflow
system minimises scaling effects and
maintenance for long distance trans-
port from the secondary alumina stor-
age silo to intermediate bins near the
pots. No turbuflow conveying pipe
or conveying pipe bend has been
changed in the last five years.
Since start-up in September 2001
the fluidflow air slide pipe has been
bringing alumina from the intermedi-
Fig. 3: Moeller fluidflow air slide pipe on top of the pot
ate bins near the pots to the bunkers
of the pots without any kind of main-
tenance. The MDPF system is thus an
integrated component and is one of
the reasons for the success and the
high performance of this smelter at
Aluminij Mostar.
Moeller Fluidflow
Especially for green field applications,
but also for retrofit projects, Moeller
Materials Handling can offer a direct
pot feeding system as Moeller fluid-
flow air slide pipe system (Fig. 2).
The alumina will be taken from the
secondary alumina silo by a Moeller
fluidflow air slide pipe. The fluidflow
feeds a so-called main intermediate
bin. This main intermediate bin will
be operated between full and half
full. From this main intermediate bin,
the alumina will be fed via fluidflow
air slide pipe along the pot room to
all pots.
The fluidflow air slide pipe along
the pot room is equipped with T-
pieces, which are connected with the
fluidflow air slide pipe on top or in-
tegrated in the superstructure of each
pot. Normally, two pots will be feed
via one T-piece. The fluidising air is
supplied by a separate rotary piston
blower. The MDPF system is working
fully automatically and is more or less
100% filled with alumina all the time.
When the bunker of a pot is full, the
bulk material cone level reaches the
fill spout discharge opening of the flu-
idflow air slide pipe, and so automati-
cally blocks the mass flow of alumina.
When secondary alumina is removed
ALUMINIUM 1-2/2007
SPECIAL
Fig. 4: Self-closed feeding spout and filling process of ore bunkers
from the ore bunker of the pot, the
pneumatic transport starts again au-
tomatically and ensures a constant
and reliable mass feed rate to the
pots. The fluidising of the secondary
alumina inside the fluidflow air slide
pipe works permanently to ensure a
constant bulk density.
The self-closing filling spout due
to the material cone level in the ore
bunker of a pot is self-regulating and
ensures continuous refilling of the
61
ALUMINIUM 1-2/2007
A L U M I N I U M S M E LT I N G I N D U S T R Y
ore bunkers during operation of the
smelting plant. The self-closed feed-
ing spout and the filling process of
ore bunker are shown in Fig. 4. Fur-
thermore, no pressure-tight sealing of
the pot is necessary, because of the
low over-pressure in the fluidflow air
slide pipe.
The main advantages of the MDPF
system are: self-regulating and con-
tinuous feeding of bunkers, absolutely
dust free operation, no generation of
fine particles, no segregation, no scal-
ing, lowest possible (over)pressure,
no pressure-tight sealing of the pot,
minimized energy consumption, min-
imized maintenance work.
Conclusion
The Moeller fluidflow direct pot feed-
ing is designed to ensure most con-
stant and reliable feeding possible of
secondary alumina to the ore bunkers
of the pot. Lowest possible conveying
velocities preserve the particle size
distribution and the flowability of the
secondary alumina and avoid scaling
effects. This most competitive system
demonstrated superiority by mini-
mal wear and maintenance, as well
as minimal energy consumption, and
last but not least by its high operating
reliability.
Authors
Dipl.-Ing. Timo Letz and Dipl.-Ing. Carsten
Duwe are with Moeller Materials Handling
GmbH, Pinneberg, Germany.
61
ALUMINIUM 1-2/2007
CO M PA N Y N E W S
Company news worldwide
Aluminium smelting industry
Alcan entertaining potential
buyers for Vlissingen aluminium
plant
Canadian aluminium major Alcan is
entertaining bids from any potential
buyers of its 200,000 tpy aluminium
smelter in Vlissingen in The Nether-
lands. Ongoing negotiations involving
a consortium of energy-intensive
companies have so far failed to satisfy
the smelters requirements for a long-
term competitive energy supply. The-
re may be some potential buyer who
will have some special way of working
with it to make it more viable. But the
smelters casthouse is good and Alcan
plans to keep it, no matter what the
outcome of the smelter. In addition,
the smelter has a good carbon plant
that has been modernised.
Malaysias Jabat Yakin plans
300,000 tpy aluminium smelter
Malaysian construction firm Jabat
Yakin is seeking financial backers for
a proposed 2.3 billion ringgit (US$
631m) aluminium smelter in eastern
peninsular Malaysia. Jabat Yakin has
hired two Islamic finance institutions,
Kuwait Finance House and AmIslam-
ic Bank, as well as accounting firm
PriceWaterhouseCoopers, to arrange
the financing for the project, which
will be located in the state of Pahang.
The Malaysian company is in talks
with potential joint venture partners
Chalco and Dubal. The project will
yield 300,000 tpy of aluminium in a
first stage of production.
Hydro opens office in Iceland
Hydro has opened a North Atlantic
office in Reykjavik to support its stra-
tegy of repositioning and growth in its
primary aluminium activities. Hydro
is presently involved in supplying
technology to the Nordural alumi-
62
nium plant, and has also delivered
technology to the hydrogen filling
station that supplies Icelandic buses
with emission-free fuel. Hydro is able
to build on its position as a technolo-
gy leader in the aluminium industry
and intends to invest in a 600,000
tpy aluminium smelter in the 2010 to
2015 period, based on the availability
of power. Hydros new North Atlan-
tic office in Reykjavik is headed by
Bjarne Reinholdt.
Qingtongxia Glencore talks
on the rocks as smelter project
faces delay
Glencores plans to co-operate with
Qingtongxia Aluminium Group have
hit problems as the future of a 250,000
tpy smelter project planned by the
Chinese company looks increasingly
uncertain. Glencore signed a memo-
randum of understanding with Qing-
tongxia in August 2006, which was de-
signed to facilitate investment in the
Chinese companys planned 250,000
tpy aluminium smelting project. But
talks have gone badly. Besides pro-
blems with Glencore, Qingtongxia has
yet to receive government approval
for the project. The delay is probably
linked to Beijings plan to clamp down
on the aluminium industry and to its
stricter stance on new aluminium pro-
jects. New smelting projects in Chi-
na are likely to find it more difficult
to win government approval as the
government is not encouraging new
projects.
CVRDs Mozambique coal
project moving forward
CVRDs plans to produce coal at
Moatize, Mozambique, could move
forward quickly once the rail link to
transport the coal from mine to port is
established. CVRD is still studying the
possibility of later producing primary
Norsk Hydro
aluminium at the site. Local reports
are correct that output at Moatize
could reach a total of 12 million tpy
of coal, of which around 40 per cent
would be metallurgical (coking) coal
and 60 per cent steam (thermal) coal.
The metallurgical coal would be for
export. Studies are under way into
developing the thermoelectric plant.
Likewise, the company continues to
study the possibility of using the en-
ergy produced at the proposed ther-
moelectric plant to fuel aluminium
smelting facilities that could also be
set up at Moatize. In theory it should
be cheaper to produce primary alumi-
nium in Mozambique than in Brazil
due to the current high cost of elec-
trical energy in Brazil.
Ormet finalises power deal with
AEP
Ormet Corp. and American Electric
Power (AEP) have finalised their long-
term agreement under which AEP will
provide power to Ormets Hannibal,
Ohio, operation. Two of Ormets six
potlines could now restart as early as
mid-December 2006 as 250 employees
were called back to work. Effective 1
January 2007, the pact places Ormets
Hannibal facilities back into AEP ser-
vice territory, where the company will
provide power at US$ 43 per MWh
through the end of 2008. Following a
two-year period, Ormet will then be
able to obtain power at the same rate
as other large industrial users in the
Ohio service territory.
ALUMINIUM 1-2/2007

Dubal completes US$ 280m
expansion to take capacity to
861,000 tpy
Dubal has completed a US$ 280 milli-
on expansion which will raise capaci-
ty by 100,000 tpy to 861,000 tpy. The
two expanded potlines, 7B and 9B,
were officially inaugurated at a gala
ceremony attended by His Highness
Sheikh Hamdan. Expansion of the
two potlines began in November and
December 2005, adding 128 cells to
potline 7B and 36 cells to potline 9B.
Dubal is working on a further small in-
cremental 60,000 tpy expansion that
will lift capacity to around 925,000
tpy from the start of 2007.
Ashapura Minechem to set up
aluminium project in Orissa
Ashapura Minechem, one of Indias
larger bauxite miners, plans to set
up an alumina refinery, aluminium
smelter and power plant in the mi-
neral-rich state of Orissa in eastern
India. The company has submitted
a proposal to the Orissa government
for an integrated aluminium project
in the bauxite-rich Koraput district
in southern Orissa. The state govern-
ment is vetting the proposal before a
memorandum of understanding is si-
gned. Ashapura has yet to decide on
the size of the project and on how it
will be developed. The alumina refi-
nery may be set up in the first phase
and the smelter in the second phase.
The integrated aluminium project is
expected to cost come US$ 2 billion. A
formal announcement on Ashapuras
aluminium project can be expected
early in 2007. The company has re-

 
A L U M I N I U M S M E LT I N G
Alcan to pilot advanced AP50 technology
through US$ 550m facility in Quebec
Alcan will invest US$ 550 million in a 60,000 tpy AP50 pilot plant at its
Complexe Jonquire site in Canada. The development plan is the first step
in a planned ten-year US$ 1.8 billion investment programme in Quebecs
Saguenay-Lac-Saint-Jean region. The new AP50 pilot facility will be the
cornerstone of an industrial strategy developed by Alcan with the support
of the Government of Quebec. The AP50 pilot plant is the initial step in
creating up to 450,000 tpy of new generation AP smelting capacity, based
entirely on clean, renewable hydroelectricity. Construction is expected to
begin in 2008 with first metal coming on stream in late 2010. This initial
phase would be followed by up to an additional 390,000 tpy in the Sa-
guenay-Lac-St.-Jean region by 2015. For this project the Government of
Quebec has provided financial support by means of R&D tax incentives and
loans, and has made available up to 225 MW of additional power to support
the investment programme. The agreement with the Government of Que-
bec also reinforces Alcans electrical power position in Quebec through the
long-term extension of hydraulic leases and new power contracts which
provide a secure supply of approx. 2,600 MW of low-cost power through
the year 2045.
ceived a formal invitation to begin munities and businesses. The Indone-
work on its alumina project in the sian government wants to change the
Kutch region of Gujarat by the state Asahan project into an electricity
government. company, as the government has so
far not gained any financial advantage
from the project.
Indonesia places smelters
future under scrutiny
Columbia Falls hopes to restart
The Indonesian authorities are kee- second potline in the first quar-
ping up the pressure on their Japanese ter 2007
joint venture partners to consider clo-
sing the 225,000 tpy Asahan Alumini- Columbia Falls Aluminum Co ho-
um smelter in the countrys Sumatra pes to restart the second of its five
province. The smelter has made a pro- potlines in the first quarter of 2007.
fit in only 3 of its 23 years of operation, Columbias one operating potline pro-
and Indonesia is now suggesting it be duces approx. 35,000 tpy of alumini-
closed when the existing joint venture um. While alumina might be readily
agreement runs out in 2013, and the available, securing power for alumi-
freed power used to supply local com- nium smelters in the U. S. northwest
 



  
 




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ALUMINIUM 1-2/2007 63
CO M PA N Y N E W S
has been a hurdle for production. The
plant produces primary aluminium in
sheet and T-bar.
RusAl starts Khakass smelter
RusAl has begun the ramping up of
its Khakass aluminium smelter on 15
December 2006, the first aluminium
production facility in Russia built in
the past 20 years. The company will
initially operate the plant at 71,000
tpy and is aiming to complete in No-
vember 2007. Total investments into
the project exceeded US$ 750 million.
The 300,000 tpy smelter is located in
the Republic of Khakassia. It operates
RA-300 reduction cells. The overall in-
vestment into the regional infrastruc-
ture amounted to some US$ 21m. The
launch of the new production facility
created around 1,000 jobs.
SUAl plans US$ 1.5b smelter
for northern Kazakhstan
Russian aluminium producer SUAl
plans to build a US$ 1.5 billion alu-
minium smelter in northern Kazakh-
stan that could add 500,000 tpy to the
companys output from 2011. SUAl
will begin the feasibility study in ear-
ly 2007. If the feasibility study is suc-
cessful, as well as the following agree-
ments with the Kazakh government,
construction will start in 2008. SUAl
has already signed a memorandum of
understanding with Kazakh subsidia-
ry of US energy company AES Corp to
supply power to the smelter from the
Ekibastuz GRES-1 power station for
20 to 30 years.
Alcan completes purchase of
cathode business in France
Alcan has completed the acquisition
of the remaining 70% stake of Carbo-
ne Savoie, and certain related techno-
logy and equipment, from GrafTech
International for US$ 135 million
less certain price adjustments. Today,
Alcans proprietary world-leading Pe-
chiney AP Series Smelting Technology
already uses Carbone Savoies advan-
ced graphitised cathode blocks. With
64
revenues of approx. US$ 114 million
in 2005, Carbone Savoie is a leading
and profitable producer of cathode
blocks, including a growing share of
graphitised cathode blocks, as well as
Bauxite and alumina activities
RusAl acquires 56.2% stake in
Eurallumina refinery
RusAl successfully completed the ag-
reement with Rio Tinto to purchase a
56.2% stake in the Eurallumina alu-
mina refinery in Italy. The remaining
43.8% share of Eurallumina is owned
by Glencore. Ownership of the asset
will be consolidated under United
Company RusAl, when the merger
RusAl, SUAl and Glencores alumina
assets is completed in 2007.
Alcan looks Madagascar for
bauxite and 1.5m tpy alumina
refinery
Alcan signed a memorandum of un-
derstanding with Access Madagascar
Sarl to jointly study the possibility
of developing a bauxite mine and a
1 to 1.5 million tpy alumina refine-
ry in Madagascars south eastern
Laos and Vietnam to host
new bauxite projects
Southeast Asia may soon join Australia,
Jamaica and the Republic of Guinea as
one of the worlds chief bauxite-producing
regions. The recent agreement between
Aluminium Corp of China (Chalco) and Vi-
etnam National Coal and mineral Industries
Group (Vinacomin) to mine bauxite and
produce alumina in Vietnam joins them
to a joint venture between Australias Ord
River Resources Ltd. and China Nonferrous
Metals International Mining Co Ltd. (CN-
MIM). They plan to develop a potentially
huge bauxite project at the Bolaven Pla-
teau in southern Laos. Ord has just moved
to establish a Laos-based joint-venture
company with CNMIM in order to consoli-
date the companies commercial position
in the country. The partners believe that
sidewall blocks and ramming pastes.
The business employs approx. 500
people at two sites, both in close pro-
ximity to Alcans R&D centre in Vor-
eppe, France. N
Manantenia District. Alcan and Ac-
cess will undertake a concept study
to review the bauxite reserves and
logistics, estimate costs and look at
social and environmental conditions.
This concept study is expected to be
complete in the second quarter of
2007, and could then lead to feasi-
bility studies. On the basis of these
studies, Alcan will explore options
that could make an alumina refinery
project viable.
Nanshan to expand alumina
capacity to 700,000 tpy
Chinas Nanshan Group will expand
alumina refining capacity by 75 per
cent to 700,000 tonnes per year by
September 2007. Nanshan is due to
finish the first phase expansion of its
new alumina refinery by the end of
November, with capacity to produce
400,000 tonnes per year. The com-
the Bolaven Plateau project could hold be-
tween 2 and 2.5 billion tonnes of bauxite.
Laos is said to be well-suited for the devel-
opment of bauxite and alumina projects.
The country has ample hydroelectric power
resources and already exports power to
Vietnam and Thailand. Furthermore, Laos,
Vietnam and China have signed an agree-
ment to develop the Trans-Asian Railway
(TAR) network, which will link China to
several Southeast Asian nations. Under an
agreement announced in January 2006
between Chalco and Vinacomin, the com-
panies are to build a US$ 2 billion bauxite
mining and alumina project in Dak Nong.
The alumina refinery will have a capacity of
1.9 million tpy, rising to 4 million tpy in a
second phase of its development.
ALUMINIUM 1-2/2007

pany then plans to increase capacity
by another 300,000 tonnes per year.
Output from the new plant will be
used for its own aluminium smelters
owned by Nanshan Group and Shan-
dong Nanshan Industrial Co. Nanshan
Group and Shandong Nanshan have
156,000 tpy and 36,000 tpy of elec-
trolytic aluminium capacity respec-
tively.
Chalco to commission third
phase of Pingguo refinery in
2008
Aluminium Corp. of China (Chalco)
plans to commission a 900,000 tpy
third phase expansion at its alumi-
na refinery in Pingguo in Chinas
southern Guangxi autonomous region
in late 2008. The expansion will take
alumina capacity at the Pingguo works
also known as Chalcos Guangxi
Branch to 1.8 million tpy. Chalco
also plans to increase smelting capaci-


BAUXITE AND ALUMINA
ty at Pingguo from 130,000 to 250,000
tpy, though no date has been set for a
second phase of construction.
Guangxi Huayin to commission
alumina refinery in 2007
Guangxi Huayin Aluminium Corp
plans to commission a 1.6 million
tpy alumina refinery project in Octo-
ber 2007, as part of a growing drive
by the government of the region to
strengthen its aluminium industry.
Construction of Guangxi Huayins
project started in June 2005.
Romanias Alro plans
alumina capacity upgrade
Romanian aluminium producer Alro
plans to invest US$ 50 million over
the next two years in upgrading the
alumina refinery at its subsidiary
Alum. The investment will be used to
modernise the main production faci-
lities at Alum, to cut the consumption
of materials and energy, upgrade the
thermal power plant and to align the
plant to European labour environ-
ment protection standards. The work
will involve a temporary complete
shutdown of the plant. The upgrade
will lift capacity at the refinery from
500,000 to 600,000 tpy. Beyond that,
Alro aims to increase capacity to 1
million tpy by 2010.
Iamgold to sell bauxite assets
to Bosai for US$ 46m
Toronto-based Iamgold Corp has
signed a deal with Chinese alumina
producer Bosai Minerals Group to
sell its bauxite assets for US$ 46 mil-
lion. Under the agreement, Iamgold
will sell interests in Omai Bauxite
Mining Inc and Omai Services Inc
to Bosai for approx. US$ 28 million
in cash. Bosai will also assume US$



 

 


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CO M PA N Y N E W S
18 million in third-party debt. If the
deal is approved by regulatory autho-
rities, the transaction took place on
31 December 2006. The sale is con-
sistent with Iamgolds aim to focus
on its core assets. Bosai based in
southwest Chongqing province to the
east of Sichuan plans to double its
200,000 tpy alumina refining capacity
to 400,000 tpy within the next two to
three years.
BHP in talks to take a third of
Globals US$ 2.8b alumina refin-
ery project
BHP Billiton has begun talks with
Global Alumina Corp to take a 33.3
per cent equity stake in its US$ 2.8
billion alumina refinery project in
Guinea. BHP would assume the role
Secondary aluminium smelting
and recycling activities
Hydro Deeside aims to boost
sales to offset energy costs
Hydro Aluminium Deeside plans to
lift production to 55,000 tpy to boo-
st sales by the end of next year in a
bid to offset soaring electricity prices.
Over the past three years, the plants
spending on electricity has more than
doubled. Currently the plant pays 4.6
pence per night unit and 7 pence per
day unit. Deesides current electricity
contract is 64% higher than the previ-
ous 18 month contract which ran out
in October, while that contract was
60% higher than the one before. The
recycling and remelting plant located
in Wrexham in northeast Wales pro-
duces more than 40,000 tpy of extrusi-
on ingots. Hydro Aluminium Deeside
produces extrusion ingot from 90%
remelted aluminium scrap.
Alcan invests US$ 7m in UBC
recycling at Neuf-Brisach
Alcan will invest US$ 7 million in
a special sheet Rhenalu facility in
France to recycle aluminium used
66
of project manager and operator and
will lend as much as US$ 50 million
to Global Alumina to help fund a fea-
sibility study. Under the agreement,
Global Alumina and BHP would each
own a third of the project, Dubal one
quarter, with Mubadala Development
Co taking one-twelfth. If the transiti-
on goes ahead, the potential partners
would receive shares in Global Alu-
mina and reach separate shareholder,
project-management and off-take ag-
reements. BHP, Dubal and Mubada-
la Development Co have agreed to
provide US$ 100 million of interim
financing for the project, which will
be guaranteed by Global Alumina and
Guinea Alumina. The refinery, to be
built at the inland town of Bok, is
scheduled to come on stream in the
first half of 2009.
N (Idalsa) is facing a financial crisis,
beverage cans (UBC). The new ca-
pacity will come on stream by the
start of 2008 and will turn the site at
Neuf-Brisach into Europes only ful-
ly integrated UBC processing, rolling
and finishing facility. The investment
will promote beverage can recycling
in Europe. In addition to the Neuf-Bri-
sach plant, in Europe Alcan operates
recycling and rolling facilities in Sin-
gen, Germany.
RusAl aims for 500,000 tpy of
secondary aluminium by 2011
RusAl plans to produce some 500,000
tpy of secondary aluminium by 2011
through acquisitions and through
building its own production plants.
Such a strategy would see RusAl
surpass capacity of Aleris Recycling
works in Germany, Europes largest
secondary aluminium producer,
which produces 400,000 tpy, and
compete directly with Asias largest
producers, Shanghai Sigma Metals in
China and Daiki Aluminium in Japan.
RusAl has recently acquired one pro-
ducer, Tsvetmet Services, based in the
Samara region. The company owns
Resal, also in Samara, which was set
up by RusAl in 2000. In 2005, the
Russian government has encouraged
RusAl to buy secondary aluminium
assets and already RusAl has bought
secondary aluminium assets in the
Rostow, Samara and Leningrad regi-
ons. The plan to produce 500,000 tpy
would give RusAl more than 60% of
the Russian market. It has been esti-
mated that there are 440 businesses in
Russia that produce aluminium alloys
from scrap.
Spanish secondary aluminium
producer Idalsa in trouble
Spanish secondary aluminium pro-
ducer Iberica de Aleaciones Ligeras
struggling under the weight of 26
million euros (US$ 33.4m) in debt,
and sources at European secondary
aluminium producers were reporting
that the company based in Zaragoza
in Aeragon had filed for bankruptcy
protection on 1 November 2006. The
news did not surprise the market as
Idalsa, which produces around 30,000
tpy of alloy, was a supplier to Man-
zoni-Bouchot, the French die-caster
that filed for bankruptcy protection
in October. Idalsa was owed some 13
million euros by Manzoni. Idalsa was
set up in 1984.
Scholz buys Hungarian secondary
aluminium producer Eural
German non-ferrous and ferrous scrap
merchant Scholz AG has acquired
Hungarian secondary aluminium pro-
ducer Eural kft from Spanish group
Pansoinco SA for an undisclosed sum.
Eural, which has a capacity to produ-
ce 50,000 tpy of aluminium alloy, will
probably source scrap from Audis
manufacturing plant in Gyr and
supply aluminium alloy to automoti-
ve casting plants next to Audi. Eural is
located in Tatabanya, just 60 km from
Gyr. Eural is one of the main players
in the aluminium alloys and rod in-
dustry in Central and Eastern Euro-
pe. Scholz is one of Europes largest
scrap processors and merchants, with
ALUMINIUM 1-2/2007

12 centres in south and east Germany,
the Czech Republic and Croatia, in-
cluding eight shredders, 38 shearing
machines, nine railtrack crushers and
four cable shredders.
Century Aluminium seeks foreign
partner to increase capacity
Indian secondary aluminium pro-
ducer Century Aluminium intends
to increase its output to 50,000 tpy
from 35,000 tpy by the end of 2007,
and would like to increase output to
100,000 tpy in the long term by secu-
ring a foreign partner. A time frame
Aluminium semis
Poland
Polish aluminium manufacturer
allocates funds for German buy
Polish aluminium products manufac-
turer Grupa Kety will allocate up to
200 million zloty (around US$ 65.2m)
to buy German companies operating
in the extruded products and systems
segments. Grupa Kety is actively see-
king out a medium-sized German
company which also manufactures
and distributes extruded products.
Germany has been chosen for the size
of the market for aluminium systems
used in the construction industry.
Croatia
Croatia tries again to sell alu-
minium products maker
Croatias Privatisation Fund is trying
to sell the governments 80.2% sta-
ke in Tvornica Lakih Metala (TLM),
which is the Balkan countrys largest
producer of extruded and rolled alu-
minium products. The company has
high debts and a previous attempt to
sell the stake in September drew no
bids. The latest tender has set a mini-
mum price of 10% of the companys
nominal value in an attempt to draw
out more interest. As before, the la-
test tender notice stimulates that any
potential buyer must maintain the
companys core business, commit to
ALUMINIUM 1-2/2007
was not given for that additional ex-
pansion. India represents one of the
most attractive aluminium recycling
opportunities in the world. Recycled
aluminium consumption in India, dri-
ven by the automotive sector, is set to
boom in the next four years. Demand
for recycled aluminium from automo-
tive manufacturers is likely to increase
in India to some 350,000 tpy by 2010
from 93,700 tpy, and consumption
in the general engineering industry,
such as components for washing ma-
chines, is forecast to more than treble
to 87,500 tpy from 23,500 tpy. Indias
domestic production of 200,000 tpy is
well below those levels. N ABB will upgrade existing systems,
further investment and keep 1,400 of
the current 1,600 employees on the
payroll for two years after the signing
of a purchase contract.
Bahrain
New foil annealing furnace for
Garmco Foil Mill
Garmco Foil Mill Co., Bahrain, has
placed a second order for an indirect
electrically heated chamber furnace
with mass flow heating for the an-
nealing of aluminium foils under air
or nitrogen. Garmco is expanding its
rolling facility and inquired for an
additional aluminium foil annealing
furnace from Otto Junker, Germany.
The ordered furnace is almost iden-
tical to the furnace supplied by Otto
Junker in 2004.
The existing foil annealing facility
consists of three annealing furnaces
with a common rail mounted charging
car, nitrogen gas supply system, coil
cooling/waiting/loading stands and
steel coil racks/pallets. The ordered
new foil annealing furnace is to be
located in a new extension to the exi-
sting bay with installation scheduled
to commence in April 2007.
Garmco is supplied with feedstock
from parent company Gulf Alumini-
um Rolling Mill Co. which produces
cold rolled coil and sheet in 1xxxx,
3xxx, 5xxx and 8xxx series alloys for
ALUMINIUM SEMIS
Suppliers
Dubal awards ABB contract
to upgrade smelter
Dubai Aluminium has awarded a US$
39m contract to ABB of Zurich to up-
grade electrical and automation systems
at Dubals 861,000 tpy smelter complex
in Dubai. ABB will replace five high-volt-
age regulating rectifier transformers,
which convert alternating current (AC)
to direct current (DC), with larger units
rated at 86 MVA to increase capacity and
to allow Dubal to combine two potlines.
including high-voltage cables and low-
voltage and control cables, as well as
provide control and protection systems
and 250 kA field-oriented measuring
equipment. Commissioning of the new
system will begin in July 2007.
Aluminij dd Mostar chooses
Wagstaff equipment
Aluminij dd Mostar, aluminium producer
in Mostar, Bosnia-Herzegovina, has
placed an order with Wagstaff Inc, to
modernise their third casting station.
The new contract consists of a Wagstaff
ShurCast casting machine, an AutoCast
automated casting control system, and
LHC low head composite casting moulds
for use on all stations in the casthouse.
The equipment purchased in the new
contract is slated to be commissioned in
early 2007.
Stub milling machine for
NZAS
Stimir of Iceland has completed the de-
sign of a stub milling machine for New
Zealand Aluminium Smelters (NZAS). The
contract required Stimir to fully design a
stub milling machine able to automati-
cally mill off excess stub length whilst
the anode rod is hanging in an overhead
conveyor. The automatic stub milling
machine will ensure that all stubs are of
equal length, so as to improve electrical
conductivity, rodded anode geometry,
and removal of cast iron thimbles. These
improved parameters increase electrical
efficiency and maximise both rod avail-
ability and rod service life.
67
CO M PA N Y N E W S
a wide range of applications with a
current annual capacity of 162,000
tonnes.
Taiwan
CS Aluminium delays cold
rolling expansions
Taiwans CS Aluminium has delayed
plans to expand cold rolling capaci-
ty at its Kaoshiung works on rising
competition from aluminium rollers
in China. CS Aluminium had planned
to build a new 42,000 tpy cold rolling
line in southern Taiwan, which it ho-
ped to complete by the end of 2009.
The plan has now been postponed
indefinitely. CS Aluminium plans
to make another look at its product
mix and focus more on Taiwanese
demand going forward. The compa-
ny currently sells 70% of its produc-
tion in Taiwan and exports the rest.
CS Aluminium has also a 35,000 tpy
aluminium cold rolling mill in Ningbo
On the move
Alcoa has named Charles D. McLane as
its new Chief Financial Officer effective 1
January 2007. McLane will succeed Joseph
Muscari who will retire to become Chair-
man and CEO of Minerals Technologies Inc.
Alcoa has appointed Joseph R. Lucot Vice
President Corporate Controller and elected
him officer of the company. Alcoa elected
new vice presidents: Kevin J. Anton, Presi-
dent, Alcoa Materials Management; Olivier
Jarrault, who leads the Alcoa Fastening
Systems business; Raymond B. Mitchell,
who serves as President Alcoa Investment
Cast and Forged Products; and Wayne G.
Osborn, Managing Director, Alcoa World
Alumina Australia.
Alcoa has made several executive changes:
Michael Parker, currently General Manager,
Alcoa Materials Management, will become
Vice President of that division; Timothy
Reyes, senior Vice President of Alcoa Ma-
terials Management, will become Vice Presi-
dent of marketing for Alcoa World Alumina
and Chemicals; William Rice, Vice President
of marketing for Alcoa World Alumina and
Chemicals, will become Vice President of
68
in eastern China, which is still under-
going test-runs.
China
Private aluminium fabricator in
China plans expansion to meet
rising demand
Modern International Enterprise
(Nanhai) Holding is planning big ex-
pansions to its aluminium fabricating
and extruding capacity to meet rising
demand in China and in export mar-
kets. The privately owned Chinese
company intends to increase capacity
at a newly acquired 40,000 tpy alu-
minium extruder in Chiping, eastern
Shandong province, to 100,000 tpy by
the end of February 2007. The com-
pany intends to raise aluminium fabri-
cating capacity in Foshan, southern
Guangdong province, to 120,000 tpy
over the next five years, from 20,000
tpy. The Foshan plant produces alu-
minium alloy and aluminium bars.
mining. Rice will serve on the Halco board
and represent Alcoas interest in the CBG
Guinea Bauxite mining operations; Russell
Williams, Vice President of mining, will be-
come Vice President of mining projects in
Asia, focusing on Asian bauxite issues.
The Novelis Board of Directors has accepted
the resignation of director John D. Watson,
who informed the board of his need to step
down as a director for personal reasons.
Hydro Aluminium appointed Cecilie Ditlev-
Simonsen Executive Vice President, to join
the companys top management team with
overall responsibility for communication and
reputation management.
Rio Tinto has appointed Tom Albanese,
currently Director of Group Resources, as its
new CEO, to replace Leigh Clifford on 1
May 2007.
The President of Alcans Primary Metal Group
for the Asian Pacific area, Marco Palmieri,
has left the company to pursue other career
opportunities. His position no longer exists.
Bengt Lie Hansen has been appointed
head of Hydros Russia business unit. The
change will be effective as of January 2007.
China
Yangkuang Aluminium mulls
downstream projects
Chinas Yangkuang Ke-Au Alumini-
um Co is mulling downstream alu-
minium projects as Beijing tightens
controls on the primary aluminium
sector. Yangkuang, which operates
a 140,000 tpy aluminium smelter in
eastern Shandong province, is con-
sidering downstream projects, inclu-
ding aluminium alloy and recycling.
The company has not finalized plans
but once that is done, construction
is likely to start within the next two
years. Projects will be at least 50,000
tpy in capacity. Yangkuang exports
the majority of it aluminium ingots to
south and southeast Asia.
China
Kunshan to commission 25,000
tpy foil mill in 2007
Kunshan Aluminium Co (KAC), owned
by Hanjiang Group, will commission
a 25,000 tpy foil mill in Kunshan in
eastern Jiangsu province in June 2007.
KAC intend to export the majority of
its foil and Europe is likely to be an
export destination. The mill project is
a first by Hanjiang Group, which also
owns an aluminium smelter Hubei
Danjiang Aluminium Co. Danjiang
Aluminium is targeting production
of 101,000 tonnes of aluminium ingot
in 2006. Based in Danjiangkou city
in central Hubei province, Hanjiang
Groups main business is hydropo-
wer.
U.S.A.
Indalex to sell drawn tube plant
to Spectube
Indalex Holding Corp., Illinois, agreed
to sell its assets of its drawn tube ope-
ration in Winton, North Carolina, to
Spectube Inc., Chicoutimi, Quebec.
Under terms of the definite agreement,
Spectube will acquire substantially
all of the assets of the Indalex drawn
tube business in Winton including a
dormant aluminium extrusion facility
on the site. Spectube will continue to
operate the Winton drawn tube plant,
ALUMINIUM 1-2/2007

which employs about 95 people, and
Indalex will continue to supply the
plant with extruded aluminium un-
der a supply contract with Spectube.
The Winton plant makes porthole and
seamless tube in alloys 6063, 6061,
3003, 1100 and 6463 and has nine
high-speed draw benches and four
roll straightening machines.
U.S.A.
Start-up of Kaiser Aluminums
heat-treat furnace at Trentwood
The first heat-treat furnace in Kaiser
Aluminums US$ 105 million Trent-
wood rolling mill expansion is now
at full production after going through
shakedown and start-up procedures
during the third quarter. The second
furnace is expected to be on line by
mid-2007 and the final furnace and
new stretcher by 2008. The expansi-
on had been increased from an initi-
al US$ 70 to 105 million and Kaiser
would consider further expansions if
customer demand materialised.
U.S.A.
Quanex denies Nichols unit to go
back on sales block
Quanex Corp., Houston, denies that
is will be shopping for a buyer for its
Nichols Aluminum Corp. aluminium
sheet business sometime during 2007.
The breakout of Nichols Aluminum
financial results in Quanexs fourth
quarter earning statement could be
a signal that it is thinking about sel-
ling the business. Nichols Aluminum
is an earn-and-protect business and
Quanex broke out the numbers to pro-
vide better transparency. Previously,
the numbers had been rolled into
overall results for Quanexs building
products segment.
China
Malaysian aluminium extruder
Press Metal buys upstream plant
in China
Malaysian aluminium extruder Press
Metal plans to buy a 90% stake in
Chinas Hubei Huasheng Aluminium
ALUMINIUM 1-2/2007
Order for SMS Demag
First 2-stand cold rolling mill for China
CSWA Cold Rolling Co., Ltd. (Southwest
Aluminium), China, which belongs to the
Chinalco Group, has placed an order with
SMS Demag, Germany, for the supply of a
two-stand cold rolling mill for aluminium
and aluminium alloys.
The two-stand cold rolling mill constitutes
the core of an investment package by
means of which CSWA intends to increase
its cold rolling capacity to more than half a
million tonnes per year. The new mill will
produce tin-can strip, panelling and litho
material for the printing industry. The cold
strip can be rolled up to a width of 1800
mm and a maximum final thickness of 0.15
mm.
SMS Demag is the technical and commer-
cial leader of an international consortium.
The supply scope of the company covers a
two-stand tandem mill, three Multi-Plate
plate filters for best rolling oil purity as
and Electric Co Ltd for 360m yuan
(US$ 46m) in a bid to secure raw ma-
terials and electricity for its Press Me-
tal International (PMI) downstream
aluminium manufacturing plant in
Guangzhou. Huasheng Aluminium
owns the Huasheng Aluminium Smel-
ter, which produces aluminium ingot,
and the Huasheng Electricty Genera-
tion power plant. Huasheng Alumini-
um produces 38,000 tpy of aluminium
ingots. PMI is in the process of dou-
bling its capacity to 43,000 tpy.
Japan
Kobe Steel and Alcoa to dissolve
auto sheet joint ventures
Kobe Steel and Alcoa have agreed to
dissolve two aluminium auto sheet
joint ventures. The two companies
set up the 50 : 50 joint ventures, one
based in the US and one in Japan, in
1992. The US-based company, Alcoa
Kobe Transportation Products Inc.,
focuses on research and development,
while Kobe Alcoa Transportation Pro-
ducts Ltd in Japan manufactures and
supplies aluminium sheet to Japane-
se car makers. Alcoa will acquire all
ALUMINIUM SEMIS
well as a large airwash exhaust-
air cleaning system. The new rolling mill is
equipped with state-of-the-art actuators
and technological control systems. Both
stands are designed with the CVC6 plus
technology. Such a multi-stand mill is par-
ticularly sophisticated in terms of technol-
ogy because of the temperature sensitivity
of the rolling oil used for the cold rolling
of aluminium. The mill stands as well as all
core components are manufactured in SMS
Demags workshop in Germany. Commis-
sioning is scheduled for the spring of 2009.
The Southwest Aluminium Works is con-
sidered a technology centre within the
Chinalco Group. It is located in the Xipeng
District of Chongqing, the metropolis of 30
million at the upper course of the Yangtze
river. SMS Demag AG forms part of the
Metallurgical Plant and Rolling Mill Technol-
ogy Business Area of the SMS group.
stock in the R&D venture in January
2007, while Kobe Steel will purchase
all shares in the production and sales
firm a month later. Kobe Steel will
also take over the marketing of pro-
ducts in the Japanese market. Sales at
the Japanese unit for the current year
are anticipated to be less than 20
billion (US$ 169.6m). N
The Author
The author, Dipl.-Ing. R. P. Pawlek is
founder of TS+C, Technical Info Services
and Consulting, Sierre (Switzerland), a
new service for the primary aluminium
industry. He is also the publisher of the
standard works Alumina Refineries and
Producers of the World and Primary
Aluminium Smelters and Producers of
the World. These reference works are
continually updated, and contain use-
ful technical and economic information
on all alumina refineries and primary
aluminium smelters of the world. They
are available as loose-leaf files and/or
CD-roms from the Aluminium-Verlag,
Marketing & Kommunikation GmbH in
Dsseldorf, Germany.
69
 MARKT UND TECHNIK
Umreifungstechnik mit PET-Hochleistungsband
Keine Konzessionen
an die Qualitt
Lange Zeit galten Stahlbnder als
das non plus ultra, um Masseln,
Walzbarren, Pressbolzen, Bleche
oder Profile fr den Transport zu
umreifen und sicher an ihren Be-
stimmungsort zu bringen. Auch
die Signode Packaging Systems,
ein Pionier in Sachen Umreifungs-
technik, ist mit Stahlbndern gro
geworden. Mittlerweile hat sich in
der Aluminiumindustrie in weiten
Bereichen Kunststoffband durch-
gesetzt. Vor allem das Hochleis-
tungsband Tenax aus PET bietet
in der Kombination von hoher
Bruchlast und Elastizitt einen op-
timalen Transportschutz.
Signode ist seit 1986 ein Unterneh-
men der ITW Illinois Tool Works Inc.
und beschftigt weltweit ber 7.000
Mitarbeiter in mehr als einhundert
Lndern. Rund 650 Mio. Euro Umsatz
werden allein in Europa mit Umrei-
fungstechnik erwirtschaftet. Im Jahr
1913 zunchst als Seal and Fastener
Company gegrndet, ist Signode da-
mals wie heute ein Vorreiter in die-
sem Geschft.
Das Unternehmen sieht sich als
Technologie- und Qualittsfhrer im
Umreifungsgeschft. Dafr sprechen
ber 600 aktive Patente. Qualitt
hat natrlich ihren Preis. Gerard W.
All illustrations: Signode
Mit PET-Band umreifte Palette Bolzen ...
70
Laks, der als General Manager den
Lndervertrieb fr Westeuropa leitet,
gibt unumwunden zu, dass die Umrei-
fungsmaschinen des Unternehmens
nicht zu Discountpreisen erhltlich
sind. Dafr machen wir keine Kon-
zessionen an die Qualitt unserer Pro-
dukte. Wenn jemand 20, 30 Prozent
unter unseren Preisen liegt, bietet er
im Grunde ein vllig anderes Produkt
als wir an, sagt Laks.
Das Aushngeschild unter den Si-
gnode-PET-Produkten ist die AK200-
Technologie in Kombination mit dem
Hochleistungsband Tenax: einem
hochfesten und uerst elastischen
PET-Band, das in seiner 19 bis 25
mm breiten Ausfhrung eine Bruch-
last von fast 12000 Newton aufweist.
Noch wichtiger aber als die Bruchlast
(die von Stahl ist weit grer) ist die
hohe Schlagfestigkeit des Tenax-Ban-
des. Sie ist 25 Mal grer als die von
Standard-Stahlbndern. Dieser Vor-
teil kommt beim Handling und Trans-
port zum Tragen etwa wenn ein
Ladung vom Gabelstapler fllt oder
auf einem Lkw, per Bahn oder Schiff
durchgerttelt wird. Das Tenaxband
lsst sich bis zu fnf Prozent dehnen
ohne plastisch zu verformen. Erst bei
einer Dehnung von 16 Prozent reit
es. Im Gegensatz dazu reit Standard-
Stahlband bei 0,2 Prozent und Hoch-
Strapped with PET strip: billets ...
Strapping technology
with PET high-performance strip
No concessions
on quality
Steel strips have long been regard-
ed as the non plus ultra for the
strapping of ingots, rolling slabs,
extrusion billets, sheets or sec-
tions for transport and safe deliv-
ery to their destination. Signode
Packaging Systems too, a pioneer
in the field of strapping technolo-
gy, grew large on the strength of
steel strip. Meanwhile, in wide
areas of the aluminium industry
plastic strip has become accepted.
Above all the high-performance
strip Tenax made from PET, with
its combination of high breaking
strength and elasticity, offers opti-
mum protection during transport.
Since 1986 Signode has been owned
by ITW Illinois Tool Works Inc. and
employs more than 7,000 people
worldwide in more than 100 coun-
tries. In Europe alone its strapping
technology generates a turnover of
around 650 million euros. Founded in
1913 first as Seal and Fastener Com-
pany, Signode was then, as it is now, a
front-runner in this business.
The company views itself as a
technology and quality leader in the
strapping business. Evidence of this
are over 600 active patents. Qual-
ity, of course, has its price. General
Manager Gerard W. Laks, Distributor
Sales Western Europe, states plain-
ly that the companys strapping ma-
chines are not to be had at discount
prices. We make no concessions on
the quality of our products. If anyones
prices are 20 or 30% lower than ours,
it is basically because he is offering
a product completely different from
ours, says Laks.
The flagship among Signode PET
products is AK200 technology com-
bined with the high-performance
strip Tenax: a high-strength and ex-
ceptionally elastic PET strip which, in
its 19 to 25 mm wide version, has a
breaking strength of almost 12,000 N.
Even more important than the break-
ing strength, however (that of steel
is far higher), is the high impact re-
ALUMINIUM 1-2/2007
 MARKETS AND TECHNOLOGY

sistance of Tenax strip, which is 25

times greater than that of standard
steel strips. That advantage is impor-
tant during handling and transport,
for example when a load falls off a
fork-lift or is juddered on a truck, rail
wagon or ship. Tenax strip can stretch
up to 5% without plastic deforma-
tion. It only snaps at an elongation of
16%. In contrast, standard steel strip
breaks at 0.2% and high-performance
steel strip at 6% elongation. Stretched
steel strip also essentially no longer
contracts again after extension.
A further advantage of PET strip is
that its tightness is maintained when ... und Stangen ... and bars
the strapped material cools down
stripping is often carried out at 70 C leistungs-Stahlband bei sechs Prozent Tenaxband bietet eine Reihe weitere
or more and shrinks slightly during Dehnung. Gedehntes Stahlband zieht Vorteile gegenber Stahlband. Es
this. Or when ingots are stacked in a sich zudem grundstzlich nicht mehr verkratzt nicht die Metalloberflche,
1200 kg bundle and the packet sags zusammen. kerbt sich nicht ein und verursacht
under its own weight. The PET plas- Der Vorteil des PET-Bandes besteht keine Korrosionsflecken. Die Verlet-
tic strip contracts correspondingly auch darin, dass die Spannung erhal- zungsgefahr ist geringer, da es nicht
so as to fit tightly again around the ten bleibt, wenn das umreifte Material scharfkantig wie Stahlband ist. Es ist
packaged material. In contrast steel abkhlt oft wird bei 70 C und mehr 80 Prozent leichter als Stahl, was die
strips have to be re-tightened, which umreift und dabei leicht schrumpft. Frachtkosten verringert, und bean-
incurs additional handling costs. But Oder wenn Masseln zu einem Bndel sprucht bis zu 50 Prozent weniger
if the material has left the companys von 1.200 kg gestapelt werden und Lagerraum. Und es muss nicht ent-
premises, its packaging can no longer sich das Paket unter seinem Eigen- fernt werden, wenn die Masselpakete
be re-tightened if the strapping be- gewicht staucht. Das PET-Kunststoff- in den Schmelzofen kommen. Tests
comes loose. band zieht sich entsprechend zusam- haben gezeigt, dass ein typisches
Tenax strip has a number of oth- men, so dass es weiterhin eng um das Masselbndel von 980 kg (mit ca. 50
er advantages compared with steel verpackte Material liegt. Stahlbnder Gramm Tenaxband) insgesamt 0,03
strips. It does not scratch or indent mssen dagegen nachgespannt wer- Prozent Asche hinterlsst. Die Me-
the metal surface and produces no den, was zustzliche Handlingkosten tallqualitt wird dadurch in keinster
corrosion spots. The risk of injury is verursacht. Hat das Material den Fir- Weise beeintrchtigt.
smaller, since it is not sharp-edged menhof verlassen, kann jedoch nichts Das Herzstck der Signode-Umrei-
like steel strip. It is 80% lighter than mehr an der Verpackung nachgezurrt fungsanlagen ist der AK-Umreifungs-
steel, which reduces freight charges, werden, falls die Umreifung sich lo- kopf. Entwickelt wurde er bereits in
and it occupies up to 50% less stor- ckert. den 1980er Jahren: als AK100
age space. And it does not have to be
removed when the ingot packs are
transferred to the melting furnace.
Tests have shown that a typical ingot
bundle of 980 kg (with about 50 g of
Tenax strip) produces a total of 0.03%
ash. This has no adverse effect at all
on the metal quality.
The centrepiece of Signode strap-
ping machines is the AK strapping
head. This was developed as early as
the 1980s: as the AK100 first for steel
strips and then as the AK200 for plas-
tic, and in the mid-1990s then for pol-
yester. The AK200-HD head enables
a tightening tension of up to 6000 N.
No other strapping head on the mar-
ket can do that, stresses Laks, who
has looked after business with the

ALUMINIUM 1-2/2007 71
MARKT UND TECHNIK
Begutachtung eines Masselbndel nach einem Falltest
Assessment of an ingot pack after a fall test
zunchst fr Stahlbnder, als AK200
anschlieend fr Kunststoff, Mitte
der 1990er Jahre dann fr Polyester.
Der AK200-HD-Kopf leistet eine Zug-
spannung bis zu 6000 Newton. Das
kann kein anderer Umreifungskopf
im Markt, betont Laks, der seit 1996
das Geschft mit der Aluminiumindu-
strie betreut. hnlich anspruchsvoll
sind auch die Leistungswerte fr den
Verschluss. Das patentierte Z-Weld
Verschlussverfahren garantiert eine
Verschlussstrke von 90 Prozent.
Dieser Vorteil ergibt sich daraus,
dass Signode nicht weg-, sondern last-
abhngig umreift. Eine wegabhngige
Umreifung hat den Nachteil, dass
die Bespannung stoppt, sobald ein
Gegendruck erfolgt. Demgegenber
wird das Band bei der lastabhngigen
Umreifung so lange gezogen, bis eine
leichte Dehnung erfolgt. Erst dann
wird das Band unter hohem Druck
verschlossen.
Das Umreifungsband wird ebenso
wie die Maschinen von Signode selbst
produziert, und zwar in England und
Finnland. Fr Tenaxband verwendet
man jungfruliches Material, da-
mit die Elastizitt in vollem Umfang
gewhrleistet ist. Recyclingmaterial
kommt nur bei Standardband mit zum
Einsatz. Die Zutaten zur Bandherstel-
lung bleiben ein Geheimnis weniger
Kchenchefs, so wohlbehtet wie
die Rezeptur von Coca-Cola. Man will
den Wettbewerb ja nicht unbedingt
72
schlauer machen als ntig.
hnliches gilt fr die
Fertigung des AK-200-
Kopfes, der ausschlielich
in Dinslaken produziert
wird. An diesem Signode-
Standort erfolgte die Ent-
wicklung des AK-Kopfs,
hier sind rund 300 Mitar-
beiter beschftigt, hier wird
das Fertigungs-Knowhow
gebndelt.
In der Aluminiumindu-
strie wurden die ersten zwei
Maschinen mit AK200-
Kopf 1996 bei Alcan Isal
in Island zum Umreifen
von Masseln und Barren
bis mittlerweile 30 Tonnen
aufgestellt. Fr sehr schwe-
re Gter wie Bolzen kommt
PET-Tenaxband in der Brei-
te von 19 bis 25 mm zum Einsatz. Fr
Bolzen wird 25 mm breites Band ver-
wendet, fr das Verpacken von Mas-
seln reicht dagegen 19 mm breites
Hochleistungsband. Bei weniger ho-
hen Ansprchen (z. B. fr Profilver-
packungen) wird PET-Standardband
in Breiten zwischen 12 und 16 mm
verwendet.
Mehr als 2.600 AK-Kpfe sind mitt-
lerweile weltweit und branchenber-
greifend im Markt. Und jede Woche
kommen weitere hinzu, so Laks. 890
davon sind AK200-Kpfe fr Polyes-
terband. In der Aluminiumindustrie
sind etwa 155 AK200-Kpfe im Ein-
satz. Hydro Aluminium ist laut Laks
komplett mit Signode-Maschinen
bzw. AK200-HD-Kpfen ausgers-
tet, die in Umreifungsmaschinen fr
Stahlband nachgerstet wurden.
Auslieferungen der vergangenen
Monate betreffen unter anderem den
Verkauf von AK200 19mm-Anlagen
fr Masseln nach Albras in Brasilien.
Alba Bahrain hat neue AK200-HD-
Anlagen in Auftrag gegeben. CBA or-
derte fr seine brasilianische Htte
eine Kombimaschine mit AK100/200-
Kpfen, die fr 25 mm Stahl- und 19
mm Polyesterband ausgelegt ist. Eine
Umstellung von PET auf Stahlband
kann brigens innerhalb von 15 Mi-
nuten erfolgen, denn die Bauart der
AK100- und 200-Kpfe ist identisch.
An Assan Aluminium in der Trkei
ging eine Stahlbandanlage fr Coils,
aluminium industry since 1996. Simi-
larly impressive are the performance
figures for the closure. The patented
Z-weld closure process guarantees a
closure strength of 90%.
This advantage stems from the fact
that Signode straps not in a path-de-
pendent but in a load-dependent way.
Path-dependent strapping has the dis-
advantage that the tightening stops as
soon as there is a counter-pressure.
In contrast, during load-dependent
strapping the strip is tensioned until
a slight extension takes place. Only
then is the strap sealed under high
pressure.
Both the strapping strips and the
machines are produced by Signode
itself, in England and Finland. For
Tenax strip virgin material is used,
to guarantee the full extent of its elas-
ticity. Recycled material is only ever
used for standard strip. The ingredi-
ents for strip production remain a se-
cret between a few master-chefs, as
well-protected as the recipe for Coca-
Cola. One does not want to make the
competition any more cunning than
necessary.
The same applies to the production
of the AK200 head, which is made ex-
clusively in Dinslaken. The AK head
was developed at the Signode site in
Dinslaken, where 300 people are em-
ployed and all the production know-
how is concentrated.
In the aluminium industry the
first two machines with AK200 heads
were set up in 1996 at Alcan Isal in
Iceland for strapping ingots and bars
now up to 30 tonnes. For very heavy
goods such as billets PET Tenax strip
of width 19 to 25 mm is used. For bil-
lets 25 mm strip is used, while in con-
trast 19 mm high-performance strip is
enough for packing ingots. In less de-
manding cases (e.g. for section pack-
ing) PET standard strip from 12 to 16
mm wide is used.
Meanwhile, more than 2,600 AK
heads have been marketed world-
wide and in many branches. And the
number is increasing every week, says
Laks. 890 of them are AK200 heads
for polyester strip. In the aluminium
industry about 155 AK200 heads are
in use. According to Laks Hydro Alu-
minium is completely equipped with
Signode machines and AK200 heads,
ALUMINIUM 1-2/2007

retrofitted in strapping machines for
steel strip.
Deliveries in the last few months
include for example the sale of AK200
19 mm units for ingots to Albras in
Brazil. Alba Bahrain has ordered new
AK200-HD units. For its Brazilian
smelter CBA ordered a combination
machine with AK100/200 heads, de-
signed for 25 mm steel and 19 mm
polyester strips. Besides, conversion
from PET to steel strips can take place
within 15 minutes, since the structure
of the AK100 and AK200 heads is
identical. A steel strip unit for coils to
be heat treated has gone to Assan Alu-
minium in Turkey. Dubal is currently
converting from steel to plastic.
The remaining approximate-
ly 1,700 aggregates sold are AK100
heads for steel strips. Many have been
giving good service day after day for
over 20 years. Occasionally they are
cleaned and maintained, or a blade
or conveyor wheel has to be replaced.
There are, however, hardly any other
parts affected by wear. According to
Laks, at 2,000 to 2,500 euros per year
maintenance costs are the lowest on
the market. This is also because the
technical components are on the out-
side of the head and therefore easy
to reach.
It might be thought that such reli-
ability is not very good for business,
since ultimately one wants to sell ma-
chines. But the company stays true
to its philosophy, which can be ex-
pressed as, How can we improve our
work today for the sake of tomorrow.
Improve, in order to make the cus-
tomers work easier, save costs, and
ensure that the goods arrive at their
destination undamaged. That pays
in the long term. As Laks explains,
Since the customers are happy with
the machine, we ensure long-term
sales of the associated strip.
Besides, demand is increasing con-
tinually. Laks reports that business
with the AK heads is going well. So
far they are mainly used in the smelt-
er industry. Almost two-thirds of all
smelters use AK200 heads, with an
upward trend since more and more
companies are converting from steel
to polyester strip. Americans are
lagging rather behind in this develop-
ment, says Laks. They are even
ALUMINIUM 1-2/2007
MARKETS AND TECHNOLOGY
die wrmebehan-
delt werden. Dubal
rstet derweil von
Stahl auf Kunststoff
um.
Die anderen rund
1.700 verkauften Ag-
gregate sind AK100-
Kpfe fr Stahlbn-
der. Manche leisten
seit ber 20 Jahren
ihren Dienst, Tag fr
Tag. Gelegentlich
werden sie gereinigt
und gewartet, muss
ein Messer ausge-
tauscht werden oder
ein Frderrad. Wei-
tere Verschleiteile
gibt es jedoch kaum.
Die Kosten fr die
Instandhaltung sind
mit 2.000 bis 2.500 Zustzliche Sicherung mit dem neuen Signode Flex Stretch Net
Euro pro Jahr laut The new Signode Flex Stretch Net for optimum transit security
Laks die niedrigsten
im Markt. Auch weil sich die Technik also noch viel Spielraum fr Wachs-
an der Auenseite des Kopfes befindet tum, sowohl in Nord- wie in Sdame-
und damit einfach zu erreichen ist. rika. Erste AK200-HD-Maschinen fr
Man knnte meinen, diese Zuver- Bolzen sind jedoch schon in den USA
lssigkeit sei ein Stck weit schdlich und Kanada installiert.
frs Geschft, denn schlielich will Langfristig drften auch der chine-
man ja auch Maschinen verkaufen. sische und russische Markt attraktiv
Doch man bleibt der Firmenphiloso- werden. Dort dominiert noch das Um-
phie treu, die da lautet: Wie knnen reifen mit Stahlband oder sogar mit
wir unsere Arbeit von heute fr mor- Aluminiumdraht.
gen verbessern. Verbessern, um dem Der Marktbedarf in Europa ist
Kunden die Arbeit zu erleichtern, Ko- dagegen weitgehend gedeckt. Zumin-
sten zu ersparen und sicherzustellen, dest in den Httenbetrieben. Wachs-
dass die Ware ohne Schden beim tumspotenziale bietet dagegen die Re-
Adressaten ankommt. Das zahlt sich cyclingbranche und die Verarbeitung.
langfristig aus. Denn sind die Kunden Signode hat hier vor allem die Umrei-
mit dem Werkzeug zufrieden, verdie- fung von Aluminiumwalzprodukten
nen wir langfristig am Verkauf des wie Bleche und Coils im Visier.
zugehrigen Bandes, so Laks. Zur Marktbearbeitung wurde da-
Im brigen wchst die Nachfrage her erst krzlich ein neues Global
kontinuierlich. Das Geschft mit den Specialist Team gebildet, das von
AK-Kpfen luft laut Laks gut. Sie wer- Laks gefhrt wird. Es soll die Kontakte
den bislang vor allem in der Httenin- zu den Signode-Niederlassungen, die
dustrie eingesetzt. Fast zwei Drittel al- die OEMs weltweit betreuen, intensi-
ler Htten verwenden AK200-Kpfe. vieren. Auerdem soll das Team die
Tendenz steigend, denn immer mehr lokalen Key Account Manager von Si-
Betriebe rsten von Stahlband auf Po- gnode dabei untersttzen, mit Alumi-
lyester um. Die Amerikaner hinken niumhtten und -verarbeitern Kon-
dieser Entwicklung noch etwas hin- takt aufzunehmen, um sie mit Test-
terher, sagt Laks. Sie seien eben kon- versuchen von der Leistungsstrke
servativer als die Europer. Auer- des Polyesterbandes zu berzeugen.
dem sind spezielle Begutachtungen Das sollte nicht allzu schwer fallen.
bei Einsatz von PET-Band fr Alumi-
niumprodukte erforderlich. Da bleibt N
73
MARKETS AND TECHNOLOGY

more conservative than Europeans.
Moreover, special expertise is need-
ed when using PET strip for alumin-
ium products. So there is still plenty
of room for growth, in both North and
South America. However, the first few
AK200-HD machines for billets have
already been installed in the USA and
Canada. In the long term the markets
in China and Russia should also be-
come attractive. In both countries
strapping with steel strip or even alu-
minium wire is still dominant.
In contrast, market needs in Europe
have largely been covered, at least
in smelter operations. On the other
hand there is growth potential in the
recycling branch and in processing.
Here, Signode mainly has the strap-
ping of rolled aluminium products
such as sheets and coils in its sights.
To prepare the market, therefore, a
new Global Specialist Team was re-
cently formed, which is led by Laks.
It aims to intensify contacts with the
Signode establishments which look
after OEMs worldwide. In addition,
the Team will support Signodes lo-
cal Key Account Managers in mak-
ing contact with aluminium smelters
and processors, in order to persuade
them of the effective performance of
polyester strip by means of tests. That
should not be difficult at all.
N

Alcutec Engineering

German know-how for Russian aluminium

recycling complex
MVS (Mordovvtorsyrio) in the
capital of the Russian republic of
Mordovia, Saransk, has started
the construction of an aluminium
recycling complex with an annual
capacity of 60,000 tonnes of metal
for a wide range of alloys. The
plant concept is based on the most
advanced equipment available for
this kind of production. The tech-
nology is provided by the German
company Alcutec Engineering,
which also implemented all the

Photos: Alcutec Engineering

engineering services and supplied
the required equipment. The indi-
vidual components were manufac-
tured in Germany with some com-
ponents supplied from the UK, the
Netherlands and France. The steel
structures were also built in Ger-
many, since quality control and
monitoring are very painstaking
and therefore costly, as Christoph
Schmitz, Managing Director of Al-
cutec, stresses.
Key equipment for the melting sec-
tion are two tilting rotary drum fur-
naces with a capacity of 25 tonnes
each, having a cycle time (tap to tap)
of 4 hours. To be able to process all
kinds of aluminium scrap of different
origin the complex is equipped with
Technological details of the tilting rotary drum
furnace were published in ALUMINIUM 2004,
issue 3, 172-177, and issue 4, 288-290.
In der Bauphase: Einer von zwei kippbaren Drehtrommelfen ...
In the building phase: one of two tilting rotary drum furnaces
a high performance shredder system sary plant also includes a state-of-the-
with adjacent classifiers. Two rever- art gas scrubbing system to complete
beratory furnaces, each of 25 tonnes the plant set-up. This shows that the
bath capacity with a melting rate of Russian customer regards environ-
3 tonnes per hour, facilitate casting. mental protection as extremely im-
The melting capacity is required to portant and makes no concessions in
be able to melt no-go production and that respect.
clean scrap. The MVS contract is worth ap-
The arrangement of the furnaces proximately 10 million euros. The
permits continuous casting. A dual contract was awarded in May 2006
casting line with automatic stacker and delivery was concluded a few
produces remelt ingots. To obtain high days ago once reconstruction of the
quality standards an in-line, degas- shed for the plant had been completed.
sing and filtration system is arranged The customer assigned to us highly
ahead of the casting line. The neces- qualified staff, with whom outstand-

74 ALUMINIUM 1-2/2007

ing collaboration was possible, says
Schmitz in appreciation of the good
co-operation during the performance
of the contract work.
For Alcutec the Russian market
is very important and is a mainstay
of the companys business. After the
construction of plants at MOPM, Mos-
cow and VTORMET, MVS is the third
complete aluminium recycling com-
plex supplied to Russia by Alcutec.
A further advantage in this was that
Russian import duties are reduced in
the Province of Mordovia in order to
encourage the establishment of in-
dustrial companies there. A propor-
tion of the casting alloys produced go
towards meeting domestic needs, but
MVS aims to export the remainder.
With the current investments MVS is
preparing itself for the fact that as the
Russian domestic automobile market
develops into one of the countrys
largest purchasers, castings of better
quality will be needed. The plant
now supplied makes MVS not only
Russias largest secondary melting
operator, but also puts the company
in a position to compete fully with Eu-
ropean suppliers, says Schmitz.
Important as the Russian market
may be for Alcutec, the USA and
emerging Asian markets such as In-
dia are also interesting market regions
for Alcutecs engineering business.
In contrast, it is very difficult to get
orders for complete new projects in
Germany, where as a rule existing
but largely superannuated recycling
plants are being modernised.
Nobody builds as sturdily
as we do
Alcutec Engineering provides profes-
sional engineering services for the sec-
ondary aluminium industry, starting
from feasibility studies, through basic
and detailed engineering, to project
management. This also includes the
supply of technology and process
know-how as well as the development
of new processes. As Schmitz points
out, Our professional service ensures
a conclusive engineering and plan-
ning phase. We strive to avoid critical
interfaces between equipment and
plant selections. A particular point of
differentiation from the competition is
ALUMINIUM 1-2/2007
MARKETS AND TECHNOLOGY
und kippbaren Herdfen mit Schmelzleistung fr MVS
and tilting hearth furnaces with the melting power for MVS
expressed as, Nobody builds as stur- company supplies all other equip-
dily as we do. For a recycling furnace ment used in the industry, such as in-
to operate for 20 years or even longer got casting lines with stacker, waste
without problems, for example with- gas scrubbing plants and auxiliary
out cracks in the external masonry or equipment.
the furnace housing, a warp-resistant The business activities comprise
steel structure with correspondingly professional services for erection,
large wall thickness is needed. That commissioning and plant mainte-
may be somewhat more expensive, nance, including the development of
but it is an investment which pays in maintenance systems. One activity is
the long term, says Schmitz. operational assistance by providing
Alcutec supplies proprietary equip- experts with a detailed service report
ment consisting of tilting rotary drum in their field. This service enables the
furnaces, hearth furnaces, charging customer to update the methods of
systems, chip drying systems as well an existing plant or to use the latest
as other tailor-made equipment for technology efficiently.
the secondary aluminium industry. The quality requirements of the
In co-operation with other firms the different aluminium alloys are stead-
Alcutec rstet russische Umschmelzhtte aus
Fr die russische MVS in der Republik Der MVS-Recyclingkomplex ist auf eine
Mordowien hat Alcutec Engineering aus Jahresleistung von 60.000 Tonnen ausge-
Niederzier einen Komplettauftrag ber legt. Mit der gelieferten Anlage entwickelt
zwei kippbare Drehtrommelfen, zwei sich MVS nicht nur zur grten Um-
kippbare Herdfen mit Schmelzleistung schmelzhtte in Russland, das Unterneh-
inklusive Nebeneinrichtungen wie Abgas- men wird auch gegenber europischen
reinigung, Khl-, Elektro- und Hydraulik- Anbietern absolut wettbewerbsfhig,
einrichtungen sowie Schredderanlage sagt Alcutec-Geschftsfhrer Christoph
abgewickelt. Schmitz. Der Auftrag hat ein Volumen von
Die Kapazitt der Recyclingfen betrgt rund zehn Millionen Euro und wurde vor
je 25 Tonnen. Die Herdfen haben eine wenigen Tagen ausgeliefert. Es ist der drit-
Kapazitt von ebenfalls je 25 Tonnen bei te russische Komplettauftrag fr Alcutec.
einer Schmelzleistung von drei Tonnen pro Weitere Projekte fr den russischen Markt
Stunde. sind in Vorbereitung, so Schmitz.
75
MARKETS AND TECHNOLOGY
ily becoming stricter, particularly for
the most important customer of the
secondary aluminium plants the
automotive industry. Quality means
minimum deviations from the target
alloy composition, no or negligible
mechanical inclusions and very little
gaseous contamination. On the other
hand, the plant must operate eco-
nomically successfully. Considering
spiralling energy costs and the more
and more stringent environmental
regulations, this is becoming increas-
ingly difficult.
However, the most critical factor
is the shortage of suitable aluminium
scrap. The quantity of this raw mate-
rial is limited worldwide and numer-
ous countries compete to get their
share, with the result that scrap prices
are high. The secondary aluminium
industry is therefore compelled to
process even scrap of low quality, in
other words scrap that is heavily con-
Kippdrehtrommelofen im Einsatz bei der Firma Oetinger.
Tilting rotary drum furnace in use at Oetinger in Germany
taminated by organic and inorganic
contaminants and compound metals.
Clean scrap originating from produc-
tion waste or no-go parts is generally
not available to refiners in the second-
ary aluminium industry.
One key question for a production
manager is therefore, how much alu-
minium is produced from a certain
quantity of scrap. This is expressed
by the metal recovery factor, namely
the ratio between metal produced and
scrap consumed. This is easy to use in
76
an economical evaluation since prices
of scrap and metal are readily avail-
able. However, sometimes confusing
information is published on recovery:
for instance, a value of 90% or even
higher, although the scrap processed
may have had a metal content of only
70%. So the figures given have to be
looked at carefully. They may be only
valid for a very specific case such as
a plant that remelts clean scrap un-
der strictly controlled operating con-
ditions.
Melting such material in a rever-
beratory furnace may result in a metal
loss as high as 70%, 80%, or even more,
unless a special metal pumping system
is used. The melting loss may than be
reduced to reasonable values of 2 to
5% of the metal contained in the feed
material. This technology, however,
entails operation with a metal heel
in the furnace, and there are difficul-
ties in obtaining the requested metal
analysis if the
metal charged
is not very well
specified. In fact
this can only
be the case in a
closed-loop re-
cycling process
in a downstream
plant.
As is gener-
ally known, the
secondary alu-
minium indus-
try is divided
into refiners and
remelters. While
refiners produce
alloys from a
wide variety of
scrap, remelters
produce their
alloys from clean scrap of defined
analysis. Consequently the key tech-
nology for the melting equipment
is different. Reverberatory furnaces
either designed as hearth furnace or
twin-chamber furnaces additionally
equipped with feeding systems for
small particles are used in remelt-
ing plants that process defined clean
scrap with only little organic contami-
nation.
Refiners, in contrast, need dif-
ferent melting equipment. The key
equipment for melting at a refining
plant is the rotary drum furnace, to-
day typically designed as a tilting
rotary drum furnace says Schmitz.
This technology permits processing
of almost all kinds of scrap and is
particularly suitable for scrap heavily
contaminated with organic and inor-
ganic matter and for material with a
large specific surface area. Selecting
the proper equipment for the kind of
plant operation remelting or refin-
ing is the principle task of the plant
owner and his engineers.
Low metal loss and also favourable
energy consumption are not the only
criteria. Safe and reliable operation
is an important factor as well. The
equipment must be able to withstand
the sometimes harsh treatment by
the operators under severe operat-
ing condition and must work without
down-time due to equipment failures.
So the traditional methods of equip-
ment design may not be sufficient to
achieve this target and design meth-
ods used for heavy machinery must be
applied as well, says Schmitz.
Another factor to be considered is
compliance with the environmental
standards of the plant location and
the industry. Summarising the above
facts, the plant owner may be hard
put to select the right equipment and
processes for his future plant or plant
expansion.
Further Russian projects in
course of preparation
Professional consulting services may
assist the plant owner in the deci-
sion-making process. Companies that
can provide the required consulting
service should also have proprietary
technologies and a broad product
range. This combination assures cli-
ents in the secondary aluminium in-
dustry of smooth commissioning and
trouble-free operation. Proper train-
ing and production assistance are fur-
ther steps for obtaining a plant that is
economically successful. Schmitz is
convinced that Alcutec provides this
service as well as supplying propri-
etary equipment and technology. And
he confirms that, Further projects for
the Russian market are in course of
preparation. N
ALUMINIUM 1-2/2007
MARKT UND TECHNIK
Positive Stimmung in der Branche
Deutsche Aluminium-
konjunktur luft derzeit rund
Die deutsche Aluminiumindustrie
bleibt auf Wachstumskurs. Die
ersten neun Monate des vergan-
genen Jahres verliefen fr die
Branchenunternehmen durchweg
positiv, wie Gerhard Buddenbaum,
Prsident des Gesamtverbandes
der Aluminiumindustrie (GDA),
auf einer Pressekonferenz im
November 2006 resmierte. Die
Aluminiumunternehmen konn-
ten 2006 deutlich mehr Auftrge
verbuchen. In fast allen Produk-
tions- und Verarbeitungsbereichen
weisen die Tendenzen nach oben,
so Buddenbaum. Die deutlich ge-
stiegenen Metallpreise an der Lon-
don Metal Exchange bten dabei
allerdings Druck auf die Margen
der Verarbeiter aus.
Seit geraumer Zeit ist die Stimmung
der Aluminiumindustrie positiv. Und
auch fr 2007 bleiben die Perspekti-
ven laut GDA aussichtsreich, trotz der
zu Anfang dieses Jahres in Deutsch-
land erhhten Mehrwertssteuer um
drei Prozentpunkte und der weiterhin
hohen heimischen Energiepreise.
Anzeige
www.inotherm-gmbh.de
Die Bedeutung von Aluminium hat in
den vergangenen Jahren stndig zuge-
nommen. Der Aluminiumbedarf ist im
Zehnjahresvergleich zwischen 1995
und 2005 um mehr als 50 Prozent auf
3,1 Mio. Tonnen gestiegen. Der Bedarf
wird laut GDA-Geschftsfhrer Chri-
stian Wellner auch fr das Gesamtjahr
2006 erneut leicht zunehmen.
Wichtigster Zielmarkt fr die
deutsche Aluminiumindustrie bleibt
der Verkehrssektor mit 43 Prozent
Marktanteil am Gesamtabsatz. Wei-
tere wichtige Mrkte sind der Bau-
sektor (15%), die Verpackungsindu-
strie (10%) und der Maschinenbau
(9%). Im Getrnkedosenmarkt hat
78
sich die Aluminiumdose mit der neu-
en Pfandregelung seit Mai 2006 einen
Marktanteil von rund 50 Prozent er-
obert. Das ist gemessen an frheren
zehn bis 15 Prozent Marktanteil zwar
ein beachtlicher Erfolg gegenber der
Weiblechdose, doch bewegt sich der
Dosenmarkt insgesamt gesehen noch
weit unter dem Niveau, auf dem er vor
drei bis vier Jahren war.
Produktion auf hohem Niveau
Bei der Produktion von Sekundra-
luminium, Aluminiumhalbzeug und
Formguss konnten die deutschen
Aluminiumunternehmen 2006 leicht
zulegen, bei der Weiterverarbeitung
wurde das gute Vorjahresergebnis
besttigt. Die deutschen Primralumi-
niumhtten produzierten wie in den
Vorjahren an der Kapazittsgrenze. In
den ersten neun Monaten 2006 lag die
Erzeugung von Primraluminium mit
386.700 t jedoch 22 Prozent unter dem
Vergleichszeitraum des Vorjahrs. Zu-
rckzufhren ist dieser Rckgang auf portance of aluminium has increased
die Abschaltung der Aluminiumhtte
in Hamburg. Die Produktion von Se-
kundraluminium stieg von Januar bis
September 2006 um 11 Prozent auf
596.100 t. Sorgen bereitet der Branche
der anhaltende Rohstoffbedarf boo-
mender Volkswirtschaften wie China
und Indien, die die Verfgbarkeit von
Aluminiumschrotten in Deutschland
und dem brigen Europa bedrohen.
Die 35 deutschen Halbzeugwerke
produzierten 2006 auf weiterhin ho-
hem Niveau. Bei den Press- und Zieh-
Quelle: GDA
Aluminiummrkte in Deutschland, 2005
Positive mood
in the German aluminium industry
Prospects for 2007
are good
The aluminium industry in Ger-
many is still growing. The first
nine months of last year turned
out positively for the branch, as
Gerhard Buddenbaum, President
of the German trade association
GDA summarised at a press con-
ference in November 2006. Alu-
minium companies booked many
more orders in 2006. In almost
every production and processing
sector the trend was upwards,
said Buddenbaum. However, the
considerably higher metal prices
on the London Metal Exchange put
pressure on processors margins.
Generally speaking the aluminium in-
dustrys mood is positive. And accord-
ing to the GDA prospects for 2007 are
relatively good as well, despite the
value-added tax increase (by 3%) at
the beginning of this year in Germany
and the persistently high domestic en-
ergy prices.
Over the past several years the im-
continually. A ten-year comparison
between 1995 and 2005 shows that
demand for aluminium has increased
by more than 50%, up to 3.1 million
tonnes. According to GDA Managing
Director Christian Wellner, it is again
expected to have increased slightly in
the full year 2006.
The most important target market
for Germanys aluminium industry is
still the transport sector, with a 43%
market share of total sales. Other ma-
jor markets are the building sector
Aluminium markets in Germany, 2005
ALUMINIUM 1-2/2007
 MARKETS AND TECHNOLOGY
Economic data of the German aluminium industry
Production 2005 2005 / Jan. - Sep. Jan. - Sep. Jan. - Sep.
2004 2005 2006 2006 / 05
000 t % 000 t 000 t % her Wertschpfung. Dem Wettbe-
Primary aluminium 647.9 -3.0 495.9 386.7 -22.0
Secondary aluminium 718.3 +2.1 537.2 596.1 +11.0
Rolled products 1780.9 +3.5 1354.5 1318.6 -2.7
Extruded and drawn products 527.9 +0.8 403.3 441.3 +9.4
Shaped castings 727.2 +1.6 557.2 584.0 +4.8
Further processing of aluminium: 361.7 -0.3 275.9 287.7 +4.3
Foil, tubes, aerosol & beverage cans
Sources: GDA, GDM, VAR, Stat. Bundesamt
(15%), the packaging industry (10%) produkten legte die Produktion bis
and mechanical engineering (9%). In September 2006 um 9,4 Prozent zu.
the beverage can market, with the Grund dafr war die erneut hervor-
new deposit regulation in force since ragende Exportbilanz des Verarbei-
May 2006 aluminium cans have cap- tenden Gewerbes in Deutschland.
tured a market share of approximately Bei Walzprodukten stiegen die Auf-
50%. Compared with the previous 10 tragseingnge bis September um mehr
to 15%, this is indeed a substantial als zehn Prozent. Zum Jahresende
victory over tinplate cans, although wird die Produktion Wellner zufolge
the can market viewed as a whole is ber der des Vorjahres liegen (2005:
still far below its level three or four 1,8 Mio. t). Den Branchenumsatz fr
years ago. 2006 veranschlagt der GDA auf 15
Mrd. Euro (2005: 13,9 Mrd. ), wobei
Production at a high level ein Groteil des Zuwachses auf die
gestiegenen Aluminiumnotierungen
As in previous years, primary alu- zurckzufhren ist.
minium smelters in Germany have
been producing at the limits of their Verkehr und Maschinenbau
capacity. In the first nine months of starke Wachstumstrger
2006, however, primary aluminium
production, at 386,700 tonnes, was Auch in den nchsten Jahren wird
22% down on the same period a year der Aluminiumbedarf in Deutschland
earlier. This downturn can be at- kontinuierlich wachsen, so Wellner
tributed to the closing of the HAW zu den mittelfristigen Perspektiven
smelter in Hamburg. The production der Branche. Strkster Wachstums-
by German aluminium companies trger werde weiterhin die Automobil-
of secondary aluminium, semis and industrie sein, zumal hier die spezi-
castings increased slightly in 2006, fischen Eigenschaften des Leicht-
and in the fields of further processing metalls voll zum Tragen kommen.
the good results of the previous year Weitere Absatzchancen bietet die
were repeated. Luftfahrt, besonders fr hochwertige
Between January and September Platten und Bleche aus Aluminium.
2006 the production of secondary alu- Auch der Maschinenbau weist seit
minium increased by 11% to 596,100 einigen Jahren einen kontinuierlichen
tonnes. There is concern in the branch Mehrbedarf an Aluminiumprodukten
regarding the persistent raw materials aus. Neben hochwertigen Profillsun-
demands of booming economies such gen, z. B. fr Pneumatik- und Zylinder-
as China and India, which threaten systeme, werden vermehrt Platten fr
the availability of aluminium scrap in die Kunststoff-Formgebung geliefert.
Germany and throughout Europe. Die Bauindustrie, die seit rund einem
Production by the 35 semis plants Jahrzehnt rcklufig war, ist inzwi-
in Germany was again at a high level schen ebenfalls auf dem Weg der
in 2006. In the first nine months of Besserung, wovon auch die Alumini-
the year the production of extruded umbranche profitieren wird.
and drawn products was up by 9.4%. Dass man in Deutschland trotz
This was because of the once more schwieriger Rahmenbedingungen
ALUMINIUM 1-2/2007
produzieren kann, beweist die
Aluminiumindustrie seit Jahren,
besonders bei Produkten mit ho-
werbsdruck der Niedriglohnlnder
setzen unsere Unternehmen ein
hohes Qualittsniveau, absolute
Zuverlssigkeit und groe Flexibi-
litt entgegen, so Buddenbaum.
Die hohe Wettbewerbsfhigkeit
der Branche zeigt sich vor allem
in ihren Exporterfolgen, rund 41
Prozent der gesamten deutschen
Produktion gehen ins Ausland. Die
Wachstumsraten bei den Exporten
sind in der Tat eindrucksvoll. So
stiegen die Exporte von Aluminium-
halbzeug in die EU-Staaten von 2000
bis 2005 um rund 20 Prozent. Die
Exporte nach Nordamerika nahmen
im gleichen Zeitraum, von niedrigem
Niveau kommend, um 90 Prozent
zu; hier waren in besonderem Mae
Walzspezialitten fr die Luftfahrt
gefragt. Auch die Ausfuhren nach
Sdamerika, Osteuropa oder Asien
entwickelten sich in den letzten sechs
Jahren berdurchschnittlich gut.
Branche vor groen Heraus-
forderungen
Doch bei aller positiven Grundstim-
mung: Die Branche steht vor groen
Herausforderungen und muss weiter-
hin mit Standortnachteilen zurecht-
kommen. Die hohen Energiepreise
sind ein Faktor, ber den immer
wieder in dieser Zeitschrift berichtet
wird. Die strukturellen Nachteile des
Standorts Deutschland zeigen sich
darber hinaus in vielen weiteren
wirtschaftspolitischen Facetten. Der
GDA-Prsident dazu: Wir brauchen
weniger Brokratie und eine Moder-
nisierung des Steuer- und Genehmi-
gungsrechts, um im internationalen
Vergleich weiter aufzuholen. Die eu-
ropische Aluminiumindustrie, fgte
er hinzu, werde sich nur durch ihre
eigene Innovationskraft langfristig an
den Mrkten behaupten. Marktnahe
Produkte mit hoher Wertschpfung,
viel Know-how und gut ausgebildetes
Personal und eine hohe Servicequa-
litt seien die Erfolgsgaranten, unter
denen Europa als Produktionsstand-
ort eine Zukunft habe.
N
79
MARKETS AND TECHNOLOGY
outstanding export balance of trade
achieved by processing businesses
in Germany. Order intakes for rolled
products were up by over 10%. For
the year taken as a whole, production
is expected to exceed that of last year
(2005: 1.8 million t).
The GDA estimates that branch
turnover in 2006 will amount to some
15 billion euros (2005: 13.9 billion ),
most of this increase being attribut-
able to higher aluminium prices.
Transport and mechanical
engineering a powerful im-
pulse towards growth
In the coming years too, demand for
aluminium in Germany will continue
growing, commented Wellner con-
cerning the medium-term perspec-
tives of the branch. The strongest im-
pulse for growth will still be the auto-
motive industry, all the more so since
it is here that the specific properties
of the light metal come fully into their
own. The commercial vehicle sector
could also benefit from this, since
light metal superstructures are being
adopted more and more.
Further sales opportunities are
offered by aviation, in particular for
high-grade aluminium plates and
sheets. For some years mechanical
GDA participation at UN conference on sustainability
The German aluminium association
GDA participated as a co-opera-
tion partner at the UN international
conference Creating solutions for
sustainable consumption and pro-
duction (SCP), which took place end
of last year in Wuppertal, Germany.
GDA was one of the few representa-
tives of industry at the conference and
reported on the contribution made by
the branch towards economically suc-
cessful, socially responsible and eco-
logically acceptable development.
The conference was organised by
the Centre for Sustainable Consump-
tion and Production (CSCP). Michael
Kuhndt, Managing Director of CSCP,
which was established by the United
Nations Environment Programme
80
engineering has also been using ever
more aluminium products. Besides
high-grade section solutions, for ex-
ample in pneumatic and cylinder
systems, in that market sector more
plates for moulding plastics are being
supplied. Even in the building indus-
try, which was recessive for about a
decade, the aluminium branch can
look forward to gradual recovery.
That successful production is still
possible in Germany despite difficult
boundary conditions has been am-
ply demonstrated by the aluminium
industry for years, especially with
reference to products with high val-
ue addition. Our companies are re-
sponding to the competition pressure
from countries with low labour costs
with high quality standards, absolute
reliability and great flexibility, said
Buddenbaum. The striking competi-
tiveness of the branch is apparent in
particular from its export successes.
Around 41% of total German alumin-
ium production goes abroad. Export
growth rates are in fact impressive:
for example, exports of aluminium
semis to the EU states increased by
around 20% between 2000 and 2005,
and during the same period exports to
North America grew from a low level
by 90%, with demand focused par-
ticularly on special rolled products
(UNEP) and the Wuppertal Institute
for Climate, Environment and Ener-
gy, said, Aluminium is precious and
should therefore be used efficiently.
All the more satisfying therefore,
that the German aluminium indus-
try in particular is playing a leading
role in the discussion on sustainable
production and consumption. As the
aluminium industry is also aware of
its responsibility and strengths during
the utilisation phase, in GDA we have
acquired a competent partner and
speaker for the conference.
The newly founded CSCP is the
new think tank for socially accept-
able and sustainable production and
consumption worldwide, so sustain-
able added value is one of its princi-
for the aviation industry. Exports to
South America, Eastern Europe and
Asia also developed at above-average
rates over the past six years.
A branch faced
by major challenges
Yet, despite the optimism of the pre-
vailing mood, the branch faces great
challenges and still has to overcome
location disadvantages. High energy
prices are only one factor, which has
frequently been commented upon in
this journal. The structural disadvan-
tages of Germany as a location also
emerge in many other aspects of eco-
nomic policy. On this, Buddenbaum
said, We need less bureaucracy and
an updating of tax and licensing laws
if we are to keep up with international
competition.
The European aluminium industry,
he adds, will only hold its own in the
markets in the long term by virtue of
its ability to innovate. Market-orien-
tated products with high added value,
a wealth of know-how, well-trained
personnel and high-quality services
provide the warranties of success
which Europe needs if it is to have a
future as a production location.
N
pal tasks. As GDA Managing Director
Stefan Glimm explained, The inter-
national SCP conference was an ex-
cellent forum for us to continue our
dialogue with important stakeholder
groups on aluminium and its contri-
bution to sustainable development
as part of our Aluminium for Future
Generations initiative. With its in-
volvement of many years in the field of
sustainability, the German aluminium
industry has acted as a role model for
the aluminium industry in Europe and
the rest of the world. We have de-
veloped standards for this which have
since become benchmarks for the way
the global aluminium industry does
business, said Stefan Glimm.
N
ALUMINIUM 1-2/2007

EAA launches new sustainable development indicator results
In 2002 the European Aluminium
Association (EAA) and its member
companies embarked on a pioneer-
ing journey towards measuring
sustainability. Together with the
German Wuppertal Institute for
Climate, Environment & Energy
and the Versailles University the
European aluminium industry
developed 34 measurable sustain-
able development indicators (SDI)
to scrutinise the aluminium in-
dustrys performance during the
period 1997 to 2002.
The SDI cover areas as varied as ener-
gy consumption, emissions, resource
use, product life cycles, employee
development and relations, commu-
nity relationships, health and safety,
management efforts, competitiveness,
production and revenues. The first re-
port was issued in 2004 and showed
an industry which had significantly
improved since 1997. Now EAA has
MARKETS AND TECHNOLOGY
released the 2006 report and the data
show further improvements in many
different areas such as emissions, nat-
ural resource use, recycling and work-
er safety among others. For example,
health and safety total recordable
incidents fell 63.9% between 1997
and 2005, while the industrys fossil
fuel requirements for metal produc-
tion fell 30% and direct climate gas
emissions reduced 43.5% for metal
production.
The primary aluminium sector has
reduced its CO2 emissions by 7.7% be-
tween 2002 and 2005. This reduction
is partly achieved through PFC emis-
sions reduction and partly through
energy consumption reduction. Dur-
ing this time the semi-fabrication sec-
tor reduced its emissions by an aver-
age of 5.5% per year.
The use of aluminium in cars pro-
duced in Europe has been steadily
increasing. Between 1997 and 2002,
aluminium use per car increased, on
average, 6.6% per year to 117 kg per
vehicle. Between 2002 and 2005 the
average increase per year was 4.1%
to 132 kg per vehicle.
The building indicator provides the
total quantity of aluminium used for
building and construction purposes in
Europe. The increase has continued:
from 2.11 million tonnes in 2002 to
2.5 million tonnes in 2005.
The average market share of alu-
minium cans in Europe was 56%
in 2005 compared to 50% in 2002.
On average, an aluminium can only
needs sixty days to be recycled into a
new can and be back on the retailers
shelf.
The recycling rate for cans was
52% in 2005 according to industry
statistics collected on a regular basis
from European countries. In the auto-
motive sector as well as in buildings
the aluminium recycling rate is now
95%.
N

      
   

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D C
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fo r A lum
c assttiinngg
Drache
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ALUMINIUM 1-2/2007 81
MARKETS AND TECHNOLOGY
The development of Russias packaging market
Aluminium processing technology at the forefront
With the planned merger of the
two Russian aluminium concerns
Rusal and Sual and the Swiss raw
material concern Glencore Inter-
national, the worlds largest con-
cern in the branch at any rate
with a view to the production of
aluminium and alumina is being
created. The downstream activities
of this group have until now been
less at the focus of international
reporting. Yet here too, in the pro-
duction of can stock and foils for
packaging, the group could in the
long term develop into an inter-
national competitor with a strong
market position.
United Company Rusal, created by
the merger of Rusal, Sual and Glen-
core, will produce 4 million tonnes
of aluminium and 11 million tonnes
of alumina per year and will employ
110,000 people in 17 countries on five
continents. The group will account for
12.5% of global aluminium production
and 16% of global alumina produc-
tion. These are impressive figures.
In contrast, the groups processing
sector is still more modest, but for all
that should not be ignored. The more
so since over the past few years Rusal
and Sual have invested not only in
the modernisation of their smelters
but also in that of their processing
capacities. The technological gap be-
tween Russian and Western alumin-
ium plants is gradually beginning to
close. The combination of demand-
ing product qualities with location-
related cost advantages will make the
forthcoming United Company Rusal
an effective supplier on the domestic
Russian market, which international
concerns are keeping an eye on, and
conversely a competitor in the Euro-
pean and international markets to be
taken seriously.
In total around 760,000 tonnes
of primary aluminium went to the
various sales sectors of the Russian
market in 2005. The largest purchas-
ers of aluminium are the building
and packaging sectors. These two are
about equally important and between
82
them account for around 54% of alu-
minium consumption. Third place,
with 9%, is held by the transport sec-
tor, whereas in the western industr-
ialised countries it is the largest sales
market for light metal structures and
components. Lightweight construc-
tion, however, is not yet a major issue
in Russian automotive engineering.
Russian cars contain a proportion of
aluminium slightly above 40 kg, while
over 100 kg of the metal are built into
European and American vehicles.
In contrast, consumer packag-
ing has for years been a dynamically
growing sales market in Russia. This
applies particularly to the market for
beverage cans. It is dominated by the
packaging material aluminium and is
roughly equally divided between two
producers, Rusal Rostar and Rexam.
Achenbach caster
Imports of cans cover less than 5%
of demand. Rostar, a 100%-owned
subsidiary of Rusal, built its first can
factory with an annual capacity of 1.3
billion units in 1998, in Dmitrov near
Moscow. In 2004 a second can factory
with annual capacity 1.7 billion units
was built in St. Petersburg. There, in
St. Petersburg and Moscow, are also
where the most important can fillers
are located.
Demand for beverage cans
is growing apace
In Russia demand for aluminium bev-
erage cans is growing apace. As late as
1999 the can market was still rather
insignificant, with an annual demand
for about 258 million cans. By the end
of 2006 the demand has increased
by a factor of 15, and in 2006 can
production is estimated at around 4
billion units per year. This headlong
growth will continue in the coming
years and drive can sales up to over 5
billion units. The need for aluminium
can stock will increase to over 90,000
tpy mainly for cans to be filled with
beer, alcoholic mixed drinks and car-
bonated soft drinks.
In recent years the two major can
manufacturers Rusal and Rexam have
made efforts to encourage this mar-
ket. A marketing campaign initiated in
2000 and pursued for five years aimed
to provide aluminium cans with a pre-
Achenbach
mium image. And this succeeded: in
2003 12% of Russian beer was already
being sold in aluminium cans, com-
pared with only 0.4% in 2000. The
success in the market for soft drinks
was similar, with the proportion of
beverage cans increasing by a factor
of 7 to 700 million units. Rusal itself
has a 30% market share of beer cans
(2005). In the first half of 2006 the
company produced 15,927 t of can
and lid stock, an increase of 23.5%
over the same period of the year be-
fore, attributable to the commission-
ing of a second production line at the
Rostar works in St. Petersburg.
ALUMINIUM 1-2/2007

Trend towards thinner foils
The market for aluminium foils has
also developed. Total Russian produc-
tion in this sector amounted to around
56,600 t in 2005. The most important
sales markets are the foodstuff branch
(33%) and the tobacco industry (29%).
The trend is towards thinner foils of
6 to 9 m. Global food concerns such
as Nestl and Kraft Foods are increas-
ingly turning to the Russian market
and making ever-stricter demands,
for example related to surface quality
and mechanical properties.
Rusal produces a wide range of
foils and foil composites, mainly for
confectionery and dairy products,
tobacco goods and pharmaceuticals,
and technical applications. These are
made in its two factories Sayanal and
Armenal, which produced just short
of 19,000 t of foils in the first half of information from the company, sales
2006. This corresponds to a growth
of 2.3% compared with the same pe-
riod in 2005, largely attributed to a
productivity boost at Sayanal. There,
precisely in the sector of strip and foil Armenia was founded in 2000. In Oc-
production, is emerging a new inter-
national competitor Rusal
that plans to produce
not only commodities
but also quality prod-
ucts whose manufac-
ture is technically
sophisticated: foil
qualities which need
not fight shy of com-
parison with those
provided by European
suppliers.
Sayanal, in the Re-
public of Khakassia, Peter Finnimore, in charge of
started operating in sales and marketing at Rusal
1995 and is the largest producer of
foils and composite foils in Russia.
The plant produces strip material
6 to 10 mm thick in widths of 1300
to 1650 mm and then rolls them to
foil thicknesses down to 0.006 mm,
as used for composite packaging in
Western Europe as well. Some of
the material is delivered directly to
packaging manufacturers and some
then goes for finishing. Already in
2006 work to modernise the rolling
plant began with the collaboration of
Achenbach Buschhtten in Germany.
A main aim was to boost productivity
ALUMINIUM 1-2/2007
MARKETS AND TECHNOLOGY
and modernised foil mill at Armenal
by higher rolling speeds. According to
extend throughout Russia and the CIS
states, to Southern Asia, the American
continent and Europe.
The Armenal foil rolling plant in
tober 2006 modernisation of the plant
was completed after
almost two years,
again with Achen-
bach as the supplier.
The investment pro-
gramme amounted to
over US$ 70 million
and covered the com-
plete modernisation
of six existing foil
mills including acces-
sory and environment
protection equipment.
The modernisation
programme included
the installation of supercasters,
i.e. continuous casting and rolling
units. Armenal will in future produce
25,000 tpy of foil. 18,000 t of this in
the thickness range 6 to 9 m. This
corresponds to an efficiency boost of
150%. The Armenal foil production
too need not fear international com-
parison. Around 7,000 tpy of house-
hold foil are produced.
In search of new sales markets
Yet, barely has the current modernisa-
tion programme been completed and
a capacity increase to 40,000 tpy is al-
ready being considered. The declared
aim of Rusal is to build Armenal up
to become an international player in
the foil market, as Peter Finnimore, in
charge of the Sales & Marketing sec-
tions at Rusal, explained to this jour-
nal at the Aluminium Fair in October
2006. His main objective is the quest
for new sales markets mainly with
the European and American markets
at the focus and the establishment of
long-term customer relations in Rus-
sia and worldwide.
In the future, the foil activities of
Ural Foil (around 18,000 tpy) will
have to be taken into account along
with the above Rusal capacities. Ural
Foil belongs to Sual and is the sec-
ond-largest aluminium foil producer
in Russia. The foil works was built
in 1984 in Mikhailovsk in the Sver-
dlovsk region and covers the full
technical range from melts, through
the casting of aluminium strip (0.21 to
0.40 mm) up to foil production (0.20
to 0.006 mm). The modernisation of
the plant by ABB in 2004 concerned
among other things the drive and
automation technology of the cold-
rolling mill, including technological
control systems for thickness and flat-
ness, which has distinctly improved
the foil production both qualitatively
and quantitatively.
N
83
MARKETS AND TECHNOLOGY
Audi takes EuroCarBody Award 2006
Award for innovative TT body concept
Audi is the winner of the EuroCar-
Body Award from the Automotive
Circle International for the innova-
tive body concept of the TT. model
The sports coup beat off 13 com-
petitors from around the world to
take the award. The body of the
new TT represents the first appli-
cation of the Audi Space Frame
(ASF) technology with a hybrid
construction, featuring an elabo-
rate composition of aluminium
and steel.
Audi TT Coup body structure
This prize pays tribute to the work of
Audi developers who have again pre-
sented impressive proof, in the form
of the new TT body, of how Audi leads
the way in this field. In ASF technol-
ogy, the bodys supporting structure is
made of extruded aluminium sections
and die-castings, with the aluminium
sheet panels forming a positive con-
nection and performing a load-bear-
ing role within this structure. The
components of the ASF space frame
vary in shape and cross-section de-
pending on their function like the
bones of the human skeleton, they
are made to fulfil their task as well as
possible, while having the minimum
possible weight.
In the new TT, Audi has further de-
veloped ASF technology, and added
high-strength steel to the material
84
mix. Aluminium accounts for 69 per
cent of the total body weight. Steel
components are used at the rear of the
floor assembly. The doors and boot lid
are also made of steel. This provides
an optimum distribution of axle loads,
making for superior handling.
The TT body-in-white weighs 206
kg, of which 140 kg is aluminium and
66 kg is steel; as an all-steel construc-
tion it would be 48 per cent heavier.
The aluminium components of the
ASF comprise 63 kg of sheet, 45 kg
of castings and 32 kg of extruded sec-
tions.
The new form of ASF developed
for the Audi TT has qualities that are
perfect for a sports car. The static tor-
sional stiffness of the Coup is roughly
Innovatives Karosseriekonzept ausgezeichnet
Der Audi TT ist fr sein innovatives Ka-
rosseriekonzept mit den EuroCarBody
Award des Automotive Circle International
ausgezeichnet worden. In der Karosserie
des neuen TT findet der ASF erstmals in
hybrider Bauweise seine Anwendung. Alu-
minium und Stahl werden hier aufwndig
miteinander verbunden. Bei der Karosserie
macht Aluminium 69 Prozent des Gesamt-
gewichts aus. Stahlkomponenten finden
sich im Heckbereich der Bodengruppe.
Tren und Heckklappe sind ebenfalls aus
Stahl. Die Rohkarosserie des TT wiegt 206
50 per cent higher than that of its pred-
ecessor; on the Roadster the increase
is an incredible 128 per cent.
Extremely resilient cast compo-
nents have been used in areas sub-
jected to high local forces and where
multifunctionality is required. A prime
example is the A-post node this is
a high-tech component that connects
the longitudinal member, sill, A-post
and windscreen cross-member.
Audi is profiting from its superior
wealth of experience when it comes to
joining together aluminium and steel
components. Joining is performed in
a variety of ways punch-riveting,
clinching and bonding. A fourth join-
ing technology has now been added
to the list: self-tapping screws, insert-
ed by robots, melt the surface of the
component as a result of the friction
they cause, thus penetrating fully into
the material, forming a positive con-
nection with it. Another innovative
concept used on the new TT is the
aluminium zero joint that is produced
between the roof and the side section
during laser-welding.
This technique also enhances ride
comfort by reducing vibration. It took
only a few simulation cycles on the
computer to arrive at a structure that
suppresses incipient vibration and
avoids transmission paths.
In terms of crash safety, too, the
new TT is uncompromising. This is
the second time that Audi has received
the coveted award. In 2003 Europes
most prestigious innovation prize for
body construction went to the Audi
A8. The A8 also has an ASF body.
kg, die sich auf 140 kg Aluminium und 66
kg Stahl verteilen; in reiner Stahlbauweise
wre sie 48 Prozent schwerer. Der Alu-
miniumanteil des ASF setzt sich aus 63 kg
Blechen, 45 kg Gusskomponenten und 32
kg Strangpressprofilen zusammen. Extrem
belastbare Gusskomponenten kommen
dort zum Einsatz, wo lokal hohe Krfte
eingeleitet werden und Multifunktionalitt
gefragt ist. Ein Musterbeispiel ist der A-
Sulen-Knoten er ist ein Hightech-Bau-
teil, das Lngstrger, Schweller, A-Sule und
Scheibenquertrger miteinander verbindet.
ALUMINIUM 1-2/2007
 www.
alu-bookshop.de
EINSCHLGIGE FACHLITERATUR

AUSSCHLIESSLICH RUND UM
NE-METALLE

ALLES AUS EINER HAND

SUCHEN, FINDEN, BESTELLEN

Giesel Verlag GmbH

Postfach 120158
D-30907 Isernhagen
Tel. +49 511 7304-122
Fax +49 511 7304-157
www.giesel.de vertrieb@giesel.de
MARKT UND TECHNIK
Kolbenschmidt Pierburg setzt auf AGR-Khler aus Aluminium
Markterfolg mit Abgasrckfhrung
Die Kolbenschmidt Pierburg AG
hat fr ihr neu entwickeltes Modul
zur gekhlten Abgasrckfhrung
erste Kundenauftrge verbuchen
knnen. Aktuell verfgt das welt-
weit ttige Zulieferunternehmen
ber Auftrge von drei namhaften
europischen Automobilherstel-
lern, die ein Projektvolumen von
insgesamt rund 300 Mio. Euro
darstellen.
Sowohl Diesel- als auch aufgeladene
Otto-Motoren sind angesichts der ste-
tig steigenden Anforderungen der Ab-
gasgesetzgebung ohne AGR-Khlung
knftig kaum mehr denkbar. Beim
Dieselmotor - ob im Pkw- oder Nkw-
Bereich - gilt das vor allem fr die
weitere Reduzierung der Stickoxide
(NOx). Eine besondere Bedeutung
kommt hierbei der gekhlten Abgas-
rckfhrung zu, die eine deutliche
Reduzierung des NOx-Ausstoes er-
mglicht.
Das Gruppenunternehmen Pier-
burg GmbH setzt dabei mit seiner
Entwicklung auf ein Abgasrckfhr-
Modul mit einem neu entwickelten
Khler aus Aluminium-Druckguss,
der eine kostengnstige und gewichts-
sparende Alternative zu den heute b-
lichen Edelstahlkhlern darstellt und
sich zudem die bessere Wrmeleitung
von Aluminium zunutze macht.
Der Abgaskhler senkt die Ab-
gastemperatur je nach Betriebspunkt
um ber 600 C und trgt daher nicht
nur wesentlich zur Reduzierung der
Verbrennungstemperatur und damit
der Stickoxidemissionen bei, sondern
senkt auch die Temperaturbelastung
der nachfolgenden Motorkomponen-
ten.
Auf dem langjhrigen Know-how
des Neusser Automobilzulieferers in
punkto Schadstoffreduzierung auf-
bauend hat das Entwicklungsteam
mit dem AGR-Khler aus Aluminium
eine Produktinnovation fr Diesel-
fahrzeuge konzipiert, die sich durch
eine hervorragende Langzeitkhllei-
stung auszeichnet. Dies wird durch
eine neuartige Abgasfhrung ber
speziell geformte Lamellen-Rippen
86
erzielt. Das neuartige Khlerkonzept
eignet sich sowohl fr Nieder- als auch
fr Hochdrucksysteme und kann bei
entsprechenden Motorkonzepten ins
Saugrohr integriert werden.
Bisher bestanden Khler meist
aus zusammengeschweiten Edel-
stahlblechen, was relativ hohe Ferti-
gungskosten zur Folge hat. Ein wei-
terer Vorteil von Aluminium liegt
darin, dass dieser Werkstoff eine we-
sentlich hhere Wrmeleitfhigkeit
als Stahl besitzt. So lsst sich bei rela-
tiv kleinem Bauraum eine sehr hohe
Khlleistung erzielen.
Die spezielle, patentierte Bauform
mit unterbrochener Lamellen-Rippen-
struktur ist optimal, weil die turbu-
lente Durchmischung der Abgasstr-
mung durch die Unterbrechungen ge-
frdert wird. Sie wirkt einer direkten
Versottung entgegen, frdert den
konvektiven Wrmeaustausch und
ermglicht den Stoff-, Druck- und
Wrmeaustausch quer zur Hauptstr-
mungsrichtung, was zu einem Selbst-
reinigungseffekt fhrt.
Um den Motor mglichst schnell
auf Betriebstemperatur zu bringen,
verfgt der neue Abgaskhler ber
eine wahlweise elektrisch oder pneu-
matisch geschaltete Bypassklappe.
ber diese werden die Abgase ber
den so genannten Bypasskanal am
Khler vorbei geleitet, bis die notwen-
dige Betriebstemperatur des Motors
erreicht ist.
Beim betriebswarmen Motor wird
der Bypass geschlossen, so dass der
Khler seine eigentliche Funktion
aufnehmen kann, nmlich die Tempe-
raturabsenkung der zurckgefhrten
Abgase. Durch die hiermit hervorge-
rufene, gezielte Absenkung der Ver-
brennungstemperatur in Kombinat-
ion mit der entsprechenden Sauer-
stoffreduktion wird die maximale
Stickoxidreduzierung erreicht.
Ein weiterer Vorteil des neuen
AGR-Khlers besteht darin, dass es
sich hier um ein integriertes Bau-
teil handelt, bei dem die einzelnen
Komponenten also der khlwasser-
durchstrmte AGR-Khler, die By-
passklappe, die bedarfsgerecht zwi-
Kolbenschmidt Pier-
burg successfully mar-
keting its EGR system
Kolbenschmidt Pierburg has
booked its first orders for the
newly developed cooled exhaust
gas recirculation (EGR) module.
Presently, this globally operating
auto industry supplier has orders
on hand from three renowned
European carmakers, representing
a total contract volume of around
300 million euros.
In future, both diesel and turbo-
charged gas engines will be hardly
conceivable without EGR cooling due
to the ever stricter exhaust gas regu-
lations. For diesel engines, whether
in passenger or commercial vehicles,
this is especially true of the further
reduction of nitrogen oxides (NOx)
Of special significance in this context
is cooled exhaust gas recirculation
enabling a drastic reduction of such
emissions. This exhaust gas recircula-
tion module from Pierburg comprises
a newly developed cooler made from
die-cast aluminium - a low-cost and
weight-saving alternative to todays
commonly used stainless steel cool-
ers, an option which, moreover, uti-
lizes the better heat conductivity of
aluminium.
In lowering exhaust gas tempera-
ture by over 600 C, depending on the
operating mode, the exhaust gas cool-
er therefore helps reduce combustion
temperatures and hence nitrogen ox-
ide emissions while also taking some
of the heat off the downstream en-
gine components. The long standing
know-how of this Neuss-based auto
industry vendor in terms of emission
reduction has enabled the develop-
ment team, with its aluminium EGR
cooler, to design a product innovation
for diesel engine vehicles, one char-
acteristic for its excellent long-term
cooling performance. This is achieved
through innovative exhaust gas recir-
culation using specially shaped fins.
The new cooler concept is suitable for
both low- and high-pressure systems
and can be integrated into the intake
manifold of engines with matching
design features.
To date, coolers have mainly con-
ALUMINIUM 1-2/2007

sisted of welded stainless steel sheet
metal with its comparably high pro-
duction costs. Another advantage of
aluminium is its much higher heat
conductivity versus steel. Alumini-
ums excellent heat conductivity
makes it possible to achieve a very
high cooling effect even in a relatively
small space.
Moreover, the patented discontinu-
ous fin construction is ideal, since the
turbulent mixing of the exhaust gas
flow is enhanced by these breaks. It
counteracts direct fouling, promotes
convective heat exchange and permits
an exchange of substances, pressure
and heat transverse to the mainstream
direction - this having a self-cleaning
effect.
So that the engine reaches its op-
erating temperature as quickly as pos-
sible, the new exhaust gas cooler has a
bypass valve, actuated electrically or
pneumatically. The exhaust gases are
routed through this valve and the so-
called bypass channel past the cooler,
until the required engine operating
temperature is reached.
With the engine at its operating
temperature, the bypass is closed, so
that the cooler can perform its actual
task and reduce the temperature of
the recirculated exhaust gases. The
effective lowering of the combus-
tion temperature achieved through
this process combined with corre-
sponding oxygen abatement reduces
nitrogen oxide emissions to a maxi-
mum degree. Another advantage of
the new EGR cooler is that it is an
integrated assembly in which the in-
dividual components - EGR cooler
with its coolant flow, bypass valve al-
ternating on-demand between cooler
and bypass operation, and EGR valve
ALUMINIUM 1-2/2007
MARKETS AND TECHNOLOGY
EGR-cooler-module
for controlling the EGR rate - merge
into one EGR module. Moreover, alu-
minium makes it possible to combine
the EGR module and intake manifold
into one individual component. The
result: an integrated intake manifold
module with exhaust gas recircula-
tion and cooling system.
By fine-tuning a new welding tech-
nique developed for die-cast alumin-
ium parts, it is now possible to weld
together all the internal interfaces of
the module rather than use the type of
temperature-resistant seals and sup-
plementary fasteners employed until
now.
Additionally to meeting the already
mentioned strict criteria there is also
the weight advantage of the new alu-
minium cooler. And because of the
aluminium and its inherent corrosion
protection, all requirements in terms
of durability are likewise met.
N guss ein Gewichtsvorteil. Zudem wer-
Fotos: Kolbenschmidt Pierburg
AGR-Khler-Modul
schen Khler- und Bypassbetrieb
umschaltet, und das AGR-Ventil zur
Steuerung der AGR-Rate sinnvoll
zu einem AGR-Modul zusammenge-
fasst werden konnten. Zudem erlaubt
der Werkstoff Aluminium, das AGR-
Modul und das Saugrohr in einem
einzigen Bauteil zu verbauen. Das
Ergebnis: ein integriertes Saugrohr-
modul mit Abgasrckfhr- und Ab-
gaskhlsystem.
Durch die gezielte Weiterentwick-
lung eines neuen Schweiverfahrens
fr Aluminium-Druckgussteile kn-
nen alle internen Schnittstellen des
Moduls geschweit werden, fr die
bisher temperaturbestndige Dich-
tungen und ergnzende Schrauben
eingesetzt werden mussten.
Zustzlich zur Erfllung der bereits
genannten hohen Anforderungen er-
gibt sich beim neuen AGR-Khler
durch die Wahl von Aluminiumdruck-
den durch die Werkstoffwahl und den
konstruktiven Korrosionsschutz alle
Anforderungen in Bezug auf Dauer-
haltbarkeit erfllt.
N
Pierburg-Khlereinsatz mit der speziellen
Lamellen-Rippenstruktur
Pierburg-cooling unit with the patented
discontinuous fin construction
87
ALUMINIUM IM BAUWESEN
Energieeffizientes Bauen im Fokus von
Politik und Wirtschaft
Energiesparendes und ressourcen-
schonendes Bauen sind die zen-
tralen Themen der Baubranche.
Kontinuierlich steigende Energie-
und Rohstoffpreise sowie neue
Verordnungen und Gesetze treiben
Architekten und Bauherren dazu
an, Gebude zu bauen, die immer
weniger Energie bentigen. Wie
eine hhere Energieeffizienz auch
von Gebuden erreicht werden
kann, war nicht nur Gegenstand
des Energiegipfels der Bundesre-
gierung im Oktober letzten Jahres,
auch die EU-Kommission hat
strengere Energiesparvorgaben auf
ihrer politischen Agenda. So ber-
rascht es nicht, dass die BAU 2007
im Januar in Mnchen energie-
effizientes Bauen zu einem ihrer
Schwerpunktthemen machte.
Von zentraler Bedeutung bei der Pla-
nung und Realisierung von Gebuden
ist die uere Hlle. Sie beansprucht
zwar nur rund 15 Prozent der Bauko-
sten, ist aber verantwortlich fr den
grten Teil des Energieverbrauchs
bei Heizung, Khlung, Lftung und
Beleuchtung, und dies fr Jahrzehnte.
Optimierte Fassaden erzielen dagegen
Manahmen des Gesetzgebers
Neue Energie-Einsparverordnung
Mit der Neuregelung der Energie-Einspar-
verordnung (EnEV) zum 1. Januar 2008
durch die Bundesregierung mssen
Hausbesitzer einen Pass ber den Ener-
gieverbrauch ihres Gebudes vorlegen.
Auch in Brssel sollen die Energievorgaben
der Gebude-Richtlinie ab 2009 verschrft
werden.
CO2-Gebudesanierungsprogramm
Rund drei Viertel des Energiebedarfs im
Privathaushalt wird fr Raumheizung ge-
nutzt. Ein Gutteil der Raumwrme geht
durch Wnde, Fenster, Dach, Tren oder
den Fuboden verloren. Es gibt damit ein
groes Potenzial, die Energieeffizienz zu
steigern: In den bestehenden Wohngebu-
den wird im Durchschnitt fast dreimal so
88
bereits heute einen bis zu 60 Prozent
geringeren Energieverbrauch. Dies
spiegelt sich auch im Wrmedurch-
gangskoeffizienten fr Fenster- und
Fassadenelemente wider, die von 3,4
W/m2K in den 1980er Jahren auf in-
zwischen 1,4 W/m2K gesunken sind.
Schco: Energie sparen und
gewinnen
So stellte der europische Markt-
fhrer bei Gebudehllen, Schco
International KG, auf der BAU 2007
anwenderorientierte Programmerwei-
terungen vor, mit denen sich Energie
einsparen und gewinnen lsst: Mit
entsprechenden architektonischen
Konzepten lsst sich fast die gesamte
Gebudehlle zur Energiegewinnung
durch Licht- und Sonneneinstrahlung
nutzen und hoch wrmegedmmte
Produkte aus Aluminium, Stahl und
Kunststoff tragen dazu bei Energie
einzusparen.
Ein Beispiel sind die Schco Pro-
sol-Module: Sie leiten die erzeugte
Energie ber ein spezielles Profil fr
eine verdeckte Fhrung elektrischer
Leitungen in Fassaden direkt zur ge-
wnschten Verteilung im Gebude.
viel Energie fr Heizung und Warmwas-
serbereitung verbraucht, als gem den
Anforderungen der EnEV fr Neubauten
vorgeschrieben ist.
Die Bundesregierung hat ihr Programm
zur CO2-Gebudesanierung fr den Zeit-
raum 2006 bis 2009 auf jhrlich rund 1,4
Mrd. Euro aufgestockt. Gefrdert werden
Manahmen zur CO2-Minderung und zur
Einsparung von Energie in Wohngebu-
den. Hierunter fallen z. B. die effizientere
Gestaltung der Gebudehlle durch
Wrmedmmung von Dach und Auen-
wnden oder die Erneuerung der Fenster.
Auerdem ist eine finanzielle Unterstt-
zung mglich, wenn Energiesparhuser
und Passivhuser errichtet oder erstmalig
erworben werden.
Und die unter energetischen Aspekten
entwickelte Fassade SMC 50.HI mit
einem hochwrmegedmmten Fen-
stersystem hilft Energie einzusparen.
Corus Bausysteme: Solar-
architektur mit Profiltafeln
Corus Bausysteme zeigte auf der Mes-
se, wie mit seinen Profiltafeln Kalzip
AluPlusSolar eine dachintegrierte,
regenerative Energiegewinnung mit-
tels Photovoltaik mglich wird. Die
Solarmodule und die Aluminium-
Profiltafeln werden dabei zu einer
Einheit verschmolzen. Die Solarzel-
len sind ohne Aufstnderung in die
Flche integriert. Die robuste Solar-
folie wird dauerhaft auf die Profilta-
feln laminiert. Da die Folie flexibel ist,
knnen die Profiltafeln konvex oder
konkav verformt werden. Mit Kalzip
AluPlusSolar lassen sich Tonnen-,
Shed- oder Pultdcher ebenso ein-
fach als Energiedach ausfhren wie
individuell geschwungene Formen
bis zu einer maximalen Neigung von
60 Grad.
Alcoa setzt auf Verbundplatten
Fast mutet es als Positionierung gegen
den Trend an, wenn energieeffizientes
Bauen einmal nicht in das Zentrum
der Marktkommunikation gerckt
wird. Alcoa Architectural Products
prsentierte auf der Bau 2007 u. a.
seine Marke Reynobond und setzt
auf die wachsende Nachfrage nach
Aluminium-Verbundplatten. 1,6 mal
leichter als Vollaluminium sind die
Sandwichelemente aus Aluminium-
blechen mit Polyethylenkern sehr
biegesteif und stofest. Auerdem
dehnen sich die Paneele bei Tempera-
turschwankungen zwischen -50 und
+ 80 C kaum aus. Um die Nachfrage
nach breiteren Verbundplatten bis
2.000 mm knftig noch besser befrie-
digen zu knnen, hat das Unterneh-
men mit dem Bau einer neuen Band-
beschichtungsanlage begonnen, die
speziell Aluminium in dieser Breite
einbrennlackieren kann.
N
ALUMINIUM 1-2/2007
 ALUMINIUM IM BAUWESEN

bergeordnete Trends im Fenster- und Fassadenbau

Umwelt- und Energiefragen geben den Ton an

Vernderungen der Altersstruktur,
Globalisierung und Verknappung
von Materialien, Rohstoffen und
Energie prgen die Zukunft des
Fenster- und Fassadenbaus. So
der Tenor einer Veranstaltung des
Instituts fr Fenstertechnik (ift) im
Herbst 2006, in der die Trends der
Branche beleuchtet wurden. Hier
eine Zusammenfassung:
Als zentraler Trend kristallisierte sich
die Notwendigkeit des schonenden
Umgangs mit Rohstoffen und Ener-
gien heraus. Wrmeschutz und Mate-
rialoptimierungen in der Entwicklung
von Konstruktionen seien deshalb die
bestimmenden Themen der Zukunft.
Der Bausatzgedanke, der Kompo-
nenten wie Rahmen, Beschlge, Glas,
Randverbund, Regenschutzschiene
beinhaltet, wird die alten Konstruk-
tionsnormen ersetzen. Dies bietet
Chancen fr eine schnelle und ein-
fache Variation, Differenzierung und
Innovation der Produkte.
Bei der Wrmedmmung sind die
Technologien fr die nchsten fnf
bis zehn Jahre bekannt. Gnzlich
neue Techniken fr die Zeit danach
sind notwendig, um zu substanziellen
Verbesserungen zu kommen. Beim
Isolierglas sind beispielsweise die
physikalischen Grenzen der vorhan-
denen Entwicklungslinie erreicht.
Die stndige Verbesserung und

Deutschland nehme hier weltweit eine
Spitzenstellung ein. Auch die Fen-
ster- und Fassadenbranche habe mit
der Photovoltaik und mit energetisch
optimierten Bauteilen beste Chancen,
diese Entwicklung erfolgreich zu nut-
zen. Dem ift zufolge bestimmen meh-
rere bergeordnete Trends die knf-
tige Entwicklung der Branche.
Schco International KG
Neuentwicklung von Solarzellen in
Verbindung mit Frderprogrammen
und einer Preisreduzierung ebnet
den Weg in die Fenster- und Fassa-
denbranche. Farbstoffsolarzellen er-
ffnen neue gestalterische Mglich- Structural-Glazing-Vorhangfassade
keiten.
sowie der Kommunikation genutzt
Gesellschaftstrends werden.

Techniktrends Die Notwendigkeit weiterer Energie- Produktnorm und CE-Kennzeich-

Die heutigen Konstruktionen werden
immer vielfltiger und spezialisier-
ter. Dies erfordert deshalb auch neue
Konzepte fr Entwicklung, Fertigung,
Qualittssicherung und Wartung. Hier
bedarf es einer intensiven Informati-
on der Verarbeiter, Monteure und
Nutzer seitens der Hersteller. Alte
Themen wie Wartung und Instand-
haltung bekommen dabei eine neue
Bedeutung.
Neue Konstruktionen werden
strker als Verbundkonstruktionen
ausgefhrt, die durch eine Speziali-
sierung der jeweiligen Baugruppen
Leistungseigenschaften wie Wrme-
und Schallschutz oder Einbruchhem-
mung weiter verbessern.
Das ift ist ein eingetragener Verein, der
von der Branche der Fenster-, Fassaden-,
Tr- und Torhersteller sowie ihrer Zu-
lieferer getragen wird.
sparmanahmen etabliert sich welt-
weit mit jeder neuen Erhhung der
Energiepreise als Megatrend. Deshalb
sind Bauteile und Verfahren zur Ener-
gieeinsparung gefragt.
Die Solarindustrie hat hervorra-
gende Imagewerte in Bezug auf In-
novation, Design und Akzeptanz und
kann die Positionierung des moder-
nen Fensters als Hightechprodukt mit
hherem Preisniveau einleiten.
Fr Manahmen zur Energie- und
Ressourceneinsparung gibt es natio-
nal und weltweit Frdermglichkei-
ten, die Investitionen anstoen und
erleichtern.
Die Forschungs- und Innovations-
struktur muss sich in Deutschland
auf allen Ebenen verbessern. Unter-
nehmen, Hochschulen und Institute
mssen in Kooperationen und Netz-
werken leistungsfhige Produkte
und Dienstleistungen entwickeln,
validieren und global vermarkten.
Dabei mssen neue moderne Formen
der Arbeitsteilung, der Finanzierung
nung
Die europischen Normen der Fen-
ster-, Fassaden, Tr- und Torbranche
sind weitestgehend eingefhrt und in
groen Teilen schon bindend. Die er-
sten berarbeitungen, beispielsweise
der Fassadennorm DIN EN 13830
werden bereits in Angriff genommen.
Alte Regeln bleiben dabei erhalten
und werden przisiert.
Die Anbieter von Aluminium- und
Kunststofffenstern sowie die RAL-
Gtegemeinschaften haben fr ihre
Verarbeiter konsistente und regelge-
rechte Verfahren fr die CE-Kenn-
zeichnung und die werkseigene Pro-
duktionskontrolle erstellt. Lsungen
fr handwerklich strukturierte Her-
steller befinden sich in der Entwick-
lung.
In Deutschland kann fr Nach-
weise von Fenstern und Auentren
im Rahmen der CE-Kennzeichnung
das Cascading System (Systeminha-
ber stellt Herstellern die Ergebnisse

ALUMINIUM 1-2/2007 89
 ALUMINIUM IM BAUWESEN
der Erstprfung (ITT) zur Verfgung)
oder das Share System (mehrere Her-
steller nutzen dieselben Ergebnisse
der Erstprfung (ITT)) genutzt wer-
den. Beide Systeme sind in der DIN
EN 14351-1 verankert.
Weitere Normen und Fachregeln
Die EG Richtlinie 2002/91/EG zur Er-
mittlung der Gesamtenergieeffizienz
wird in Deutschland durch die No-
vellierung der Energieeinsparverord-
nung umgesetzt. In diesem Zuge wird
auch ein Energieausweis eingefhrt,
Schco International KG
Fensterprofil mit Einsatzelement
der den Energieverbrauch eines Ge-
budes transparent macht und bei
Gebudehllen in Metall Ideen und Konzepte fr die Zukunft
European Kalzip Student Award 2007
Die Corus Bausysteme GmbH produziert
unter der Marke Kalzip Dach- und Fassaden-
systeme aus Aluminium. International ttige
Architekten nutzen Kalzip-Profiltafeln fr
ihre architektonischen Highlights. So gehrt
der neue Barajas Airport in Madrid ebenso
zu den herausragenden Referenzobjekten
wie das BMW-Zentralgebude in Leipzig
oder das Imperial War Museum North
Manchester von Daniel Libeskind. Unter
dem Motto Wrap a building! schreibt die
Kalzip Business Unit erstmals den European
Kalzip Student Award 2007 aus, der sich
an Universitten, Fachhochschulen und
Design-Schulen aus ganz Europa richtet.
Der Wettbewerb bietet dem akademischen
Nachwuchs die Mglichkeit, ihre Design-
90
Neubau, Verkauf und Neuvermie-
tung obligatorisch zu erstellen ist.
Dieser kann wahlweise ber eine Be-
darfsrechnung oder eine Verbrauchs-
messung erstellt werden. Fr Wohn-
gebude ndert sich gegenber der
Methodik der EnEV 2004 nichts. Bei
Nichtwohngebuden mssen die En-
ergieaufwendungen fr knstliches
Licht und Klimatisierung gem der
DIN V 18599 ermittelt werden, die
auch fr die Planung von Wohnge-
buden verwendbar ist.
Brandschutznachweise knnen zur
Zeit nach nationaler Norm DIN 4102
und europischer Norm EN 13501-1
gefhrt werden. Diese sind die Grund-
lage fr die Klassifizierung. Baustoffe
mit bekannter Zusammensetzung und
bekanntem Brandverhalten werden
national in DIN 4102-4 und europ-
isch in CWFT-Listen beschrieben.
Markttrends
Deutschland nimmt weltweit die
Fhrungsrolle in der Bau- und Woh-
nungstechnologie ein. Dies bietet be-
ste Chancen auch fr die Fenster- und
Fassadenbranche, aktiv zu werden.
Eine klare Unterscheidung der Pro-
dukte in einfache Konstruktionen, die
Mindestanforderungen erfllen, und
vorstellungen und innovativen Ideen fr
zuknftige Gebudehllen im Kontext mo-
derner architektonischer Anforderungen zu
entwickeln. Studenten der Fachrichtungen
Architektur und Design knnen ihre Vor-
schlge zu folgenden Themen einreichen:
Fassade
Dach
Hybridmaterialien
Optimierung bestehender Systeme.
Die Aufgabe steht im Spannungsfeld ganz
unterschiedlicher Aspekte wie kologie,
(Licht)Durchlssigkeit, Geometrien, Oberfl-
chenstruktur, Anpassung an die (natrliche)
Umgebung, Vielseitigkeit oder Standardi-
moderne Hightechfenster macht das
Angebot verstndlicher. Hightechfen-
ster mit Zusatznutzen sowie hchster
Qualitt und Gebrauchstauglichkeit
erffnen Chancen fr ein Hochpreis-
segment.
Prestigeprojekte und Events wie
die Fuballweltmeisterschaft in
Deutschland oder die Olympiade in
Peking oder London wirken wie Ka-
talysatoren fr innovatives Bauen.
Leistungsfhige Unternehmen kn-
nen hier direkt Auftrge generieren.
Kleinere Unternehmen knnen diese
durch einen Imagetransfer fr den ei-
genen Markt nutzen.
Deutschland und Europa sind in
vielen kologischen Marktsegmenten
Weltmarktfhrer. Innovativen Her-
stellern von Fenster- und Fassaden-
technologien bieten sich so Chancen
in interessanten lokalen Wachstums-
mrkten wie London, Kalifornien
oder Peking, in denen kologische
Standards immer strker gefordert
werden.
Zukunftsstudien bieten wichtige
Hinweise und Instrumente zur Be-
stimmung mglicher Entwicklungs-
linien und bei der Planung von In-
novationen. Dies gilt es seitens der
Branche zu nutzen.
N
sierung in der industriellen Massenproduk-
tion. Bewertet werden alle Einsendungen
nach den Kriterien Kreativitt, Vision, Funk-
tionalitt, Technologie, zukunftsweisende
Entwicklungen und Marktreife.
Eine europisch besetzte Architekten-Jury
ermittelt die Sieger. Die ersten beiden Ge-
winner bekommen neben einem Geldbetrag
auch die Gelegenheit, ein mehrmonatiges
Praktikum im Wiener Bro von Coop
Himmelb(l)au zu absolvieren. Die offizielle
Preisvergabe findet am 27. April 2007 im
Deutschen Architektur Zentrum (DAZ) in
Berlin statt. An dem Wochenende werden
die prmierten Arbeiten zudem im DAZ
Berlin ausgestellt.
Unter www.kalzip-studentaward.com kn-
nen interessierte Studenten ihre Arbeiten
bis zum 15. Mrz 2007 anmelden und bis
zum 13. April 2007 einreichen.
ALUMINIUM 1-2/2007

Fenstermarkt im Plus
Die Hersteller von Fenstern und
Fassaden gehen fr 2006 erstmals
seit langem wieder von einer po-
sitiven Entwicklung fr ihre Bran-
che aus, nachdem die seit ber
zehn Jahren anhaltende Talfahrt
der deutschen Bauwirtschaft ge-
stoppt ist. Schon im Oktober 2006
auf der Glasstec verkndete Bern-
hard Helbing, der Prsident des
Verbandes der Fenster- und Fassa-
denhersteller (VFF) in Frankfurt:
Wir rechnen mit einem Zuwachs
von ber fnf Prozent.
Ende 2006 zeichnete sich fr den Fens-
termarkt schlielich ein Zuwachs von
11,6 auf 12,5 Mio. Fenstereinheiten
ab. Ein Katalysator dieser Entwick-
lung: die drastisch gestiegenen Ener-
giepreise, die den Einbau moderner,
wrmegedmmter Fenster begnsti-
gen. Fr den Wohnbau rechnet die
Branche mit einem Zuwachs von 9,7
Grtes deutsches Broprojekt mit Wicona-Fassaden
Vom damaligen Klner Oberbr-
germeister Konrad Adenauer 1924
eingeweiht, galten die Rheinhallen
lange Zeit als eine der modernsten
Messeanlagen Deutschlands. In-
zwischen ist der Abbruch der Hal-
len innerhalb der stehen gebliebe-
nen historischen Auenmauer
weitgehend abgeschlossen.
Neben dem unregelmigen Recht-
eck der Fassade von rund 200 x 300
Metern bleiben der Messeturm, ein
Wahrzeichen der Stadtsilhouette, und
das alte Portalbauwerk Atrium am
Messeplatz bestehen. In die expressi-
onistische Fassade von 1924 wird ein
komplett neues riesiges Brogebu-
de integriert. Als einer der knftigen
Mieter steht bereits der Fernsehsen-
der RTL fest, der ab 2008 aus diesen
historischen Hallen senden und hier
die Deutschland-Zentrale einrichten
wird. Die Broflche betrgt insge-
samt rund 160.000 qm, RTL wird
davon rund die Hlfte beanspruchen.
Eine Nutzung des Turms ist derzeit
ALUMINIUM 1-2/2007
ALUMINIUM IM BAUWESEN
Prozent, fr den Nichtwohnbau mit ster- und Fassadenbau steht weiter-
einem Plus von 4,6 Prozent. Der Re- hin die Verbesserung der Wrmedm-
novierungsmarkt legte um fast zehn mung im Zentrum der Aufmerksam-
Prozent, der Neubau um 5,4 Prozent keit. Denn mit der Novellierung der
zu. Fr all diese Marktsegmente wa- Energie-Einsparverordnung im Jahr
ren die Vorjahrszahlen noch negativ. 2008 werden die Ansprche an die
2007 wird der Wirtschaftsbau neben Wrmedmmung der Gebudehlle
der Renovierung die treibende Rolle noch einmal erhht. Und nachdem
fr die weiterhin positive Branchen- seit Ende 2005 alle vorgehngten
entwicklung sein. Fassaden das CE-Zeichen fhren
Bei den Rahmenmaterialien fr mssen, steht ab Herbst 2007 auch
Fenster lassen sich fr 2006 und dessen Einfhrung fr Fenster und
2007 lediglich Absatztrends erken- Auentren bevor.
nen. So nahm Kunststoff 2006 ber-
durchschnittlich zu, Holz lag im
Gesamttrend, whrend Aluminium
zurckblieb. Dies drfte sich schon
im laufenden Jahr wieder ndern,
wenn sich das strkere Wachstum des
Nichtwohnbaus mit seinen hheren
Anteilen von Metallfenstern und -fas-
saden auswirkt. 2007 wird deshalb
der Aluminiumanteil voraussichtlich
berdurchschnittlich steigen. Im Fen- Quelle: VFF
noch offen, da er als Hochhaus gilt auf der Baustelle erwartet. Dabei han-
und so besonderen Anforderungen delt es sich um rund 4.300 Element-
entsprechen muss. teile mit je 100 Kilogramm Gewicht.
Die Hallen spalten sich auf in 14
Innenhfe mit Attika, Hallen- und
Auenfassade. Das Hauptvolumen
der Aluminiumfassaden, die allein
ein Gewicht von 400 bis 450 Tonnen
ergeben, liegt in den Innenhfen. Die-
se Fassade wird bis zur Erffnung im
Jahre 2008 durch die Metallbaufirma
Rupert App aus Leutkirch ausgefhrt,
die bereits mehrere Projekte dieser
Grenordnung, u. a. die NordLB in
Hannover, umgesetzt hat. Die tech-
nischen Voraussetzungen wurden
durch die Klner Architekten HPP in
Zusammenarbeit mit dem Fassaden-
planer AMP aus Bargteheide gesetzt.
Seit Oktober 2005 hat Hydro Buil-
ding Systems aktiv zur technischen
Umsetzung im Bereich Fassaden bei
den Planern beigetragen. Die jetzige
Norsk Hydro
Ausfhrung wird in der Wicona-Ele-
mentfassadenkonstruktion Wictec EL
umgesetzt. Bereits im Dezember 2006
wurden die ersten Fassadenelemente Klner Messeturm und historische Auenfassade
91
RECYCLING
Vorbericht
9. Internationaler Aluminium Recycling Kongress der OEA
Am 26. und 27. Februar 2007 steht
in Kln das Recyceln von Alumini-
um auf dem Veranstaltungskalen-
der. An diesen Tagen ldt die Orga-
nisation of European Aluminium
Refiners and Remelters (OEA) zum
mittlerweile 9. Internationalen Alu-
minium Recycling Kongress ins
Hotel Maritim ein.
Unternehmer und Mitarbeiter der
Aluminiumrecycling-Industrie, Me-
tallhndler, Journalisten, Behrden-
vertreter, Angehrige von Hochschu-
len, also alle, die mit dem Recycling
von Aluminium befasst sind, werden
sich an dem Ort treffen, wo die erfolg-
reiche Kongress-Serie vor 17 Jahren
begonnen wurde. Der Zeitpunkt der
Veranstaltung ist gnstig gewhlt. Die
Konjunktur, das begrenzte Angebot
an natrlichen Rohstoffen und der
kologische Nutzen des Aluminium-
recyclings haben Aluminiumschrott
zu einem weltweit begehrten Roh-
stoff werden lassen. Hierdurch sieht
sich die europische Aluminiumre-
cycling-Industrie vor neue Heraus-
Preview of the 9th International Alumin-
ium Recycling Congress of the OEA
On 26 and 27 February 2007 in Cologne, the
recycling of aluminium is on the calendar of
events. On those dates the Organisation of
European Aluminium Refiners and Remelters
(OEA) is inviting interested parties to what
will then be the 9th International Alumin-
ium Recycling Congress. Companies and em-
ployees in the aluminium recycling industry,
metal traders, journalists, representatives of
government authorities, in short all who are
involved with the recycling of aluminium
will meet at the place where this series of
successful congresses began 17 years ago.
The timing of the event is well chosen.
The trade position, the limited supply of
natural raw materials and the ecological
uses of aluminium recycling have promoted
aluminium scrap to become a raw material
in demand all over the world. This presents
92
forderungen gestellt, die mit einem
weitreichenden Strukturwandel der
mit dem Recycling befassten Indus-
trie verbunden ist.
Den Einfhrungsvortrag wird Sean
M. Stack halten, der Europachef von
Aleris Europe, einem Unternehmen,
dass sich erst seit kurzem in Europa
auf dem Gebiets des Aluminiumre-
cyclings engagiert. Roland Scharf-
Bergmann, Prsident der OEA, wird
in seinem Vortrag eine Positionsbe-
stimmung der europischen Alumi- beim Recyclingprozess anfallenden
niumrecycling-Industrie vornehmen,
die bestehenden Herausforderungen
darstellen und Wege zu ihrer Bewlti-
gung aufzeigen. Gnter Kirchner, Ge-
neralsekretr der OEA und Vorsitzen-
der des Global Aluminium Recycling
Committees (GARC), stellt vor allem
auf die globale Bedeutung des recy-
celten Aluminiums als Rohstoffquelle
ab. In den letzten Jahren hat vor allem
der zunehmende Abfluss von Alumi-
niumschrott nach China fr Unruhe
gesorgt. Ob zu Recht oder zu Unrecht
wird der Vortrag eines Reprsentan-
ten der chinesischen Aluminium-
Europes aluminium recycling industry with
new challenges that entail far-reaching
structural transformations in all aspects of
recycling-related industry. The introductory
lecture will be given by Sean M. Stack, Head
of European operations at Aleris Europe, a
company that has become engaged in the
field of aluminium recycling only relatively
recently. Roland Scharf-Bergmann, Presi-
dent of the OEA, will describe the position
adopted by the European recycling industry,
set out the existing challenges and indicate
ways to overcome them. Gnter Kirchner,
Secretary General of the OEA and Chair of
the Global Aluminium Recycling Committees
(GARC), will deal mainly with the global im-
portance of recycled aluminium as a source
of raw material. In recent years, above all
the increased flow of aluminium scrap to
recycling-Industrie zeigen. Die be-
deutende Rolle des europischen
Metallhandels fr die Versorgung mit
sekundren Rohstoffen wird ebenso
diskutiert wie das durch verstrkte
Schrottexporte entstandene Span-
nungsfeld.
Allein fnf Vortrge werden sich
mit technischen Neuerungen auf
dem Gebiet der Erfassung, der Auf-
bereitung und dem Einschmelzen von
Schrotten und der Verwertung der
Salzschlacke beschftigen. Der Erfolg
der Recyclingbemhungen in Europa
hngt wesentlich von den rechtlichen
Rahmenbedingungen ab. Aktuell ste-
hen weitreichende Reformen der EU-
Abfallrahmenrichtlinie an, ber die
berichtet wird. Vortrge ber beste-
hende und knftige Preisbildungsme-
chanismen und Herausforderungen
an das Recyceln von Verpackungen
runden das Bild der interessanten
Veranstaltung ab.
Nheres zum Kongress direkt bei
der OEA: Tel: +49 (0)211 451 933 oder
unter www.oea-alurecycling.org. N
China has been a cause for concern. Wheth-
er or not this is justified will be examined
in a lecture by a representative of Chinas
aluminium recycling industry. The important
part played by the metal trade in relation
to supplies of secondary raw materials will
be discussed as well, as also will the stresses
created by rising scrap exports.
No less than 5 lectures will deal with
technical innovations in the fields of the col-
lection, preparation and melting of scrap and
the recovery and use of salt slags produced
during the recycling process. The success
of recycling efforts in Europe depends sub-
stantially on the legal boundary conditions
imposed. At present far-reaching reform of
the EUs guidelines on waste are due, and
these will be reported. Lectures on existing
and future pricing mechanisms and chal-
lenges related to the recycling of packaging
materials will round off the picture of this
interesting event. More information on the
congress at www.oea-alurecycling.org.
ALUMINIUM 1-2/2007

Recycling von Folienschrotten
Hydro vollendet Metallkreislauf in Neuss
Eine Idee, eine Pumpe, ein paar
unnachgiebige Ingenieure - so
vollendet Hydro im Aluminium-
Cluster Neuss den Metallkreislauf
und strkt den engen Verbund mit
den Nachbar-Walzwerken in
Neuss und Grevenbroich.
Die Gieerei im Rheinwerk Neuss von
Hydro schmilzt nun jhrlich 22.000
Tonnen Folienschrotte aus dem Werk
Grevenbroich um. Das macht kolo-
gisch Sinn, und es hilft im Kosten-
kampf angesichts der hohen Strom-
preise, unsere Wettbewerbsfhigkeit
zu strken, sagt Werkleiter Bernhard
Eich.
Hydro erzeugt in Deutschlands
grter deutscher Aluminiumhtte
in Neuss jhrlich 224.000 Tonnen
Flssigmetall. Dagegen liefert die Gie-
erei des Werkes mittlerweile bereits
320.000 Tonnen Walzbarren an Alu-
norf nebenan, das dann Aluminum-
band an das Folienwalzwerk von Hy-
dro in Grevenbroich liefert. Die Gie-
erei muss das Restmaterial zumeist

als Metallmasseln teuer zukaufen. Um
hier zu sparen, suchte ein Team von
Ingenieuren um Projektleiter Micha-
el Jordan, zuletzt Tag und Nacht, eine
Lsung fr den kostengnstigen, aber
hochwertigen Folienschrott aus dem
Hydro-Walzwerk in Grevenbroich.
Von der bis zu 6 Mikrometer
hauchdnnen Folie, die Hydro aus
Grevenbroich fr Getrnkeverbund-
kartons in viele Lnder liefert, lieen
sich Prozessberbleibsel bisher kaum
einschmelzen. Denn auf der groen
Oberflche der Folie wirkt eine dnne
Oxidschicht wie eine Isolierung. Au-
erdem hat zusammengepresste Folie
eine Dichte, die wesentlich unter der
von flssigem Aluminium liegt. So
schwamm Folienabfall im Schmelz-
bad zuoberst auf dem flssigen Me-
tall, es entstand viel Krtze und
die dnne Folie verbrannte statt zu
schmelzen. Die Ingenieure in Neuss
kamen auf die Idee, eine elektroma-
gnetische Pumpe zu verwenden, die
flssiges Metall mit hoher Geschwin-
digkeit zirkulieren lsst. Das rotieren-
RECYCLING
de Metall erzeugt einen Wirbelstrom
im Inneren der Pumpe, die daher
Vortex (Wirbel) heit. Kommen die
40 x 40 Zentimeter groen, aus Folie
zusammengepressten Blcke in den
Schmelzofen, presst die Schwerkraft
den Folienabfall in den Wirbelstrom
und unter die Oberflche des Metalls,
wo Turbulenzstrmungen entstehen.
Im rotierenden Metallstrom zersetzt
sich der Folienblock und schmilzt
perfekt.
Ein gutes Geschft fr beide Stand-
orte: Frher konnten wir nur dicke
walzblanke Schrotte umschmelzen,
und unsere Kunden mussten ihren
Folienschrott bei unseren Konkur-
renten einschmelzen lassen, die
zudem altmodische Technologie
verwendeten, erklrt Gieereileiter
Ulrich Bollmann. Jetzt benutzen wir
vorhandene Anlagen auf neue Weise,
knnen so die dnne Folie effektiv
umschmelzen und das lohnt sich
fr uns und fr unsere Kollegen in
Grevenbroich.
N









 
   
  



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ALUMINIUM 1-2/2007 93
TECHNOLOGY
Recent advances in coil coating technology
N. C. Davies, Banbury
The application of coatings to
continuous coils has been in exist-
ence as an industrial process for
more than 50 years. The develop-
ments made over that period have
led to an increase in both scale
and speed. Coil coating has thus
become the most efficient method
of coating materials, allowing end
users to displace this important
practice from their plants as a
fixed cost and into suppliers as a
variable cost.
The future competitiveness of coil
coating within Europe has the follow-
ing drivers: product quality and dif-
ferentiation, cost and line versatility,
environmental compliance. Achiev-
ing these technical, economic and
legislative challenges is paramount
for an industry seeking to maintain
and expand in a world where global-
isation pressures exist.
Internationally, the coil coating
process is the application of thou-
sands of tons of chemicals, paints
and lacquers to millions of square
metres of surface. The fact that most
of these coating materials have been
solvent based immediately highlights
the environmental compliance chal-
lenges facing the industry. Current
and emerging legislation, such as the
Solvent Emission Directive (SED)
[1999/13/EC] in Europe, mean that
coil coaters are continuously seeking
cleaner technologies.
Additionally, the End of Life Vehi-
cle (ELV) Directive demands that the
coatings used in automotive applica-
tions are free of heavy metals, which
then impacts on the metal pretreat-
ment (the chemical layer between
substrate and paint/lacquer) chemi-
cals that must be chromium free.
Although the primary concerns with
chromium focus on its hexavalent
form, many packaging end-users are
also demanding the withdrawal of its
trivalent form which has historically
been used as a pretreatment in can-
ning and other sheet packaging.
In addition to these challenges coil
94
coaters are always looking to increase
their volume through the line. The
overall line speed is in general limited
by the time spent in the paint/lacquer
curing ovens. Time at temperature is
required to cure the organic film and
also extreme care must be taken in
balancing the coating lines fume ex-
haust system with the coatings sol-
vent emission volume. Advances have
been made in waterborne systems and
higher solid coatings and these will be
discussed further, as will alternative
cure technology processes. It should
also be stressed that probably in ex-
cess of 95% of all coated products will
be post-formed, so all alloys and coat-
ings that are specified must be toler-
ant to controlled deformation.
In coil coating for can end stock
relatively thin lacquers are applied
to aluminium: utilising advances in
line design and lacquer formulations,
some lines are now reported to be
operating at speeds above 250m/min.
This is close to the limit of speed that
can be achieved by conventional roll
coat application technology. Any po-
tential speed increases beyond this
limit will require alternative applica-
tion technologies or processes.
Cleaning
The bare aluminium strip surface
presented to the first process step of
cleaning has residual rolling oil from
the cold rolling process, oxide films
generated during the high tempera-
ture rolling passes (most evident on
magnesium-containing alloys where
MgO segregates to the
surface) and deformed or
surface active layers.
For painted products,
corrosion susceptibility, in
most instances, has been
found to be controlled by
surface active layers. This
has only been studied
in detail during the past
decade [1, 2], initially
through an industry-wide
Brite-Euram programme Fig. 1: 100 nm surface active layer on AA3105 cold rolled sheet
focussing on filiform corrosion. These
surface active layers arise from the
high level of surface shear induced
during rolling that transforms the
near surface microstructure (Fig. 1).
Deformed surfaces are character-
ised by an ultra-fine grain size that
can be stabilised by magnesium ox-
ide pinning in magnesium-containing
alloys [3]. However, it is not the fine
grain size that is responsible for the
enhanced corrosion susceptibility of
the surface layer. This susceptibility is
promoted by the preferential precipi-
tation of manganese-rich dispersoids
during annealing treatments, which is
related to the manganese solid solu-
tion level and the temperature and
time of annealing.
These deformed surface layers on
aluminium alloys are produced most
readily by hot rolling and, generally,
the layer thickness of sheet and plate
after hot rolling is of the order of a mi-
cron. The deformed layer thickness is
progressively reduced by cold rolling
so alloys that have been extensively
cold rolled have thinner deformed
layers that can more readily be re-
moved by conventional etch cleaning
operations. This means that resistance
to corrosion can be improved by in-
creasing the transfer gauge thickness
so that after cold rolling the amount of
surface to be removed at final gauge is
0.2m or less.
The primary processes for cleaning
aluminium are by spray or immersion
in either acid or alkali solutions, al-
though acid electrolytic processes are
also used [4]. A line configuration may
ALUMINIUM 1-2/2007

also include a mild pre-clean step to
reduce the lubricant residues or any
surface detritus.
Cleaning in alkaline solutions of-
ten produces a non-uniform surface
in that aluminium and its oxide are
soluble and magnesium oxide is rela-
tively insoluble, hence a roughened
surface can result. However, alkali
cleaners are very effective in the re-
moval of organics. On the other hand
an acid cleaner will consistently at-
tack both types of oxide, providing a
more uniform surface.
For historical reasons alkali clean-
ing was initially the preferred clean-
ing option but gradually there has
been a move to acid cleaners where
proprietary cleaners are based on
sulphuric acid and incorporate hy-
drofluoric acid and surfactants. The
cleaners work by the sulphuric acid
removing organics and oxides and the
HF attacking both the oxides and the
aluminium substrate: the degree of at-
tack can be controlled by the amount
of free fluoride in solution.
Pretreatment
The key functions of pretreatments
or conversion treatments after clean-
ing is both to provide good adhesion
and to provide corrosion protection.
Pretreatment application is either by
a dip/spray process followed by rins-
ing (rinse pretreatment) or by roll
coating (no-rinse pretreatment). The
volume of chemicals used in both
processes differs considerably, with
the dip/spray process giving rise to
a large volume of contaminated rinse
water requiring treatment before dis-
posal. On the other hand, roll coating
requires a precise amount of solution
to be applied uniformly across the
strip which is then dried in place; the
reaction with aluminium consumes
all of the chemicals and no products
requiring subsequent removal are
formed, thus avoiding any potential
environmental issues.
Historically chromium based pre-
treatments have been used based
on chromate (Cr VI) and chrome-
phosphate (Cr III) chemistries. Be-
ing highly acidic these pretreatments
have often compensated for any inad-
equacies in the cleaning process. For
ALUMINIUM 1-2/2007
architectural products both types of
chromium pretreatments have been
used but, with the major carcinogenic
concerns surrounding the use of Cr
VI compounds, Cr VI is not used for
packaging products.
For rinse applications with Cr VI
pretreatments the coating is formed
by the reaction of solutions containing
sodium dichromate and hydrofluoric
acid. The HF attacks the residual sur-
face oxides and aluminium, produc-
ing electrons which facilitate a redox
reaction [5,6] resulting in the reduc-
tion of the hexavalent dichromate
ion (Cr2O7) to a trivalent chromium
oxide (Cr2O3). Importantly excess
Cr VI is retained in such films and,
in downstream product applications
where these films could be damaged,
the excess hexavalent chromium re-
acts with water and the aluminium
to produce a new conversion coating
i.e. the pre-treatment system is self-
repairing. The no-rinse roll-coatable
analogue of this system typically con-
tains CrO3, HF and amorphous SiO2
as a carrier.
For rinse applications of Cr III
pretreatments, the reacting solutions
contain CrO3, phosphoric acid and
hydrofluoric acid. Similar oxidation/
reduction reactions take place to the
above, resulting in the deposition of
a trivalent chromium phosphate film.
The no-rinse roll-coatable analogue of
this system contains chromium phos-
phate, HF and a polymer, typically
polyacrylic acid, which can act both
as an adhesion promoter and corro-
sion inhibitor.
As the market moves away from
chromium pretreatments, the techni-
cal challenges are greater, not only be-
cause of the inherent corrosion resist-
ance demanded from pretreatments
but also because of the less reactive
nature of the Cr-free systems with
the aluminium strip, thereby placing
a greater emphasis on the efficiency
and quality of the precursor cleaning
step. Thus there is a greater demand
on non-Cr pretreatments to act as ad-
hesion promoters with good uniform
barrier properties.
These adhesion and barrier as-
pects can be achieved by using a
treatment to enhance the natural ox-
ide layer, such as anodising or hydro-
TECHNOLOGY
thermal treatment in water or steam.
Anodising pretreatments have been
used very effectively for many years
although they are not in widespread
use as coil line treatments. Coil line
treatments are based on fast anodising
in either sulphuric acid or phosphoric
acid and these types of pretreatment
have the advantages of speed, control
and uniformity compared to most
chemical conversion treatments (Fig.
2); they rely on a balance between
anodic film formation and chemical
dissolution of the anodic film and are
much under-utilised as chrome-free
pretreatments.
Fluorotitanic and fluorozirconic
acid based pretreatments [7] are in
fairly widespread use as chrome-free
alternatives. Such pretreatments can
certainly be effective but are more
difficult to monitor in production
compared to traditional chrome-
based systems. This is particularly an
issue where polymeric additions are
made to the formulation to improve
performance. For such systems good
adhesion is achieved through good
surface coverage of a uniform film
of either zirconium and/or titanium
oxide. However, adhesion is severely
compromised if the film is too thick
and this can lead to in-service coat-
ing failures that are unrelated to cor-
rosion sensitivity.
Pretreatment systems based on
the use of adhesion promoters such
as silanes [8], phosphonates and poly-
acrylic acids have been extensively
researched. These pretreatments can
certainly be very effective especially
when applied as monolayers rather
than thick films. They are probably
most useful when used in combina-
tion with a thin anodising treatment
(as a post-anodising step) or similar
treatment to increase the barrier film
thickness and to develop a micro-sur-
face roughness to enhance adhesion.
Paints and lacquers
Architectural: The choice of a paint
system depends on a number of
key factors including aesthetic ap-
pearance (shade, gloss, roughness),
mechanical properties (abrasion re-
sistance, scratch resistance, impact
resistance, formability), durability
95
TECHNOLOGY
Fig. 2: Schematic of electrolytic cleaning and continuous anodising film formation
(colour and gloss retention, weather-
ing resistance, corrosion resistance),
environmental impact and cost.
Most aluminium sheet will be roll-
coated (Fig. 3) with a thin backing
coat and a two-coat topcoat, although
products with up to 4 layers of topcoat
are available for specific applications.
The initial coat is the primer, its dry
thickness usually in the range of 5 to
15 microns, to provide adhesion to the
pretreated metal and it may contain
anti-corrosive pigments. The second
coat, or topcoat, is usually in the range
of 10 to 25 microns and it provides
the colour and appearance to the fi-
nal coated system along with the other
key properties required to meet the
products performance specification.
An alternative approach is to produce
a product with a basecoat (colour)
with a clear topcoat (gloss).
There are two types of resins
used in developing liquid paints for
coil coating, thermosetting and ther-
moplastic. The thermosets include
acrylics, polyurethanes, polyesters
and silicon polyesters. The polyesters
are also used in powder spray appli-
cations. The thermoplastics include
PVC-plastisols, PVDFs (polyvinyldif-
luoride) and polyamide-nylons. Each
resin type can provide a different bal-
ance of properties:
O Polyesters provide good all round
properties including very good colour
matching capability and colour reten-
tion combined with good flexibility,
hardness, resistance to weathering
and chemicals.
O Vinyls provide the best resistance
to acid, alkalis and many solvents.
The most common building block is
polyvinyl chloride (PVC). Fluorinated
versions (PVDF) offer the best protec-
tion against weathering including UV
resistance and for this reason they are
mostly used in critical applications
96
and prestige buildings.
O Acrylics provide high gloss plus
yellowing and mar resistance.
O Urethanes combine hardness and
abrasion resistance coupled to good
weathering performance.
Packaging: Coil coating for packaging
is dominated by the market for easy-
open ends for beverage cans. Can
end lacquers are normally applied
at around 1-2.5g/m2 on the external
surface and 7-10g/m2 on the internal.
The internal coating, in particular,
must withstand the high speed form-
ing process of the end (above all the
tab rivet) whilst protecting the bev-
erage from the container (and vice
versa). Historically this application
was dominated by the highly duc-
tile vinyl organosols (vinyl chloride-
vinyl acetate copolymers dispersed
in solvent) but recently a combina-
tion of environmental pressures and
consumer health concerns has led to
replacement of solvent based vinyls
with variants including:
O Water based
O Vinyl (chlorine) free
O Low BADGE (BADGE-free)
O Bisphenol A-free.
These developments are based on
epoxy-ester or polyesters with en-
hanced flexibility.
Alternative technologies
In the challenges that face the coil
coater, he/she is consistently exam-
ining alternative technologies. As part
of continuous improvement exercises,
coil coaters have worked closely with
paint suppliers in the development of
both high-solids coatings and water-
borne coatings. High solids coatings
as their name implies, have a higher
content of solid components than
conventional solvent-borne systems.
Typically coating systems with a sol-
ids content of >85% fall into this
category and, since they contain
less solvent, they offer a signifi-
cant reduction in VOC emissions
compared to conventional sys-
tems. As well as reducing emis-
sions, high-solids coatings can
impart thicker application layers
than conventional systems, lead-
ing to timesaving. The reduction
in solvent however, means that
such coatings are more sensitive to
inadequate surface preparation of the
substrate.
Water-borne coatings are systems
that predominantly utilise water as
the solvent to dissolve the binder.
Typically up to 80% of the total sol-
vent is water with the remainder
being organic co-solvents such as
glycol ethers. Such systems benefit
from large reductions in VOC emis-
sions and an associated reduction in
both fire risk and worker exposure
to organic vapours. However, due to
the corrosive nature of the water in
the formulation, special equipment
can often be required for application.
Control of humidity is also critical to
achieving the desired film formation.
Most resins have now been incorpo-
rated into water-borne coating for-
mulations and they are finding wide-
spread applications for packaging
products. For architectural products
the use of water-borne coatings has
focused more on primers rather than
the diverse range of paints used for
topcoat functionality.
Powder coating is another alter-
native, utilising 100% resin in a dry,
powdered form and working on the
principle of attraction by oppositely
charged species. The powder is de-
livered through a spray gun where it
gains a low amperage, high-voltage
positive charge.
The surface to be coated is electri-
cally grounded so that the positively
charged powder particles are attract-
ed to it. The coated surface is then
reacted in an oven where the powder
melts and fuses into a smooth coat-
ing. This has been widely used in the
post-painting of individual parts but
has had less impact, to date, in coil
coating. Within Europe Otefal S.p.a. is
the market leader for coil coating with
line speeds typically operating at up
ALUMINIUM 1-2/2007

to 20m/min. The speed has been lim-
ited by the array of electrostatic guns
that must be synchronised to achieve
uniform film coverage. However,
powder coating has the attraction of
being solvent-free and can be cured
using infra-red or induction heating
technologies.
Other application technologies for
powder include the powder cloud
technique developed by MSC of Illi-
nois and the electro magnetic brush
(EMB) application technique devel-
oped by DSM resins in Europe. The
powder cloud technology applies
powder to the coil strip as it passes
through a charged cloud of pow-
der coating. The identically charged
powder particles repel each other and
deposit on to the earthed coil strip.
The EMB approach is based on tech-
nology that it is used for laser copiers
and photocopiers.
New developments in the formu-
lation of powder coatings generally
relate to their application in packag-
ing products such as cans, where FDA
approval is still pending. Significant
advances have also been made in the
development of powder coatings for
architectural products that require
superior long-term durability and
also powders that can form thinner
applied films.
Interesting developments in oven
technology have come out of Adphos
AG [9] who have developed nir, near
infra-red ovens to be used as boost-
ers to conventional ovens or as stand
alone systems. These are small foot-
print modules that utilise high inten-
sity heat emissions from the near in-
fra-red wavelength spectrum and can
cure 20 micron coatings in less than
3 seconds as compared to say 20 sec-
onds. Using lamp systems for curing
also means that they are only switched
on when needed as compared to the
ALUMINIUM 1-2/2007
Fig. 3: Schematic of roll
coat application of paint
to the strip
continuous power requirement of
convection ovens. However, as the
solvents will be rapidly driven off, the
extraction system has to be extremely
efficient such that the LEL (lower ex-
plosion limit) is not exceeded.
Other forms of radiation curing us-
ing ultraviolet (UV) or electron beam
(EB) have been practised since the
late 1960s. Although the growth rates
of these technologies have been rela-
tively slow, they have been continu-
ous. Conceptually radiation curing
could solve many of the coil coaters
problems; they are liquid coatings
applied to the substrate surface via
roll coating and cured at room tem-
perature in seconds without volatile
materials being lost from the surface.
However barriers to their use exist,
including the capital equipment costs
involved and the limited availability
of formulations for particular applica-
tions.
Electron beam and ultraviolet
curing have developed in parallel
since the 1960s due to their similari-
ties. Companies which produce UV
curable formulations will generally
also produce EB curables, the main
difference being that UV requires
a photoinitiator in the formulation
whilst EB does not. The absence of a
photoinitiator is EBs main advantage
over UV since photoinitiator residues
remain in cured coatings and prompt
worries over health, odour etc. Hence,
UV coatings have not been used in
coil coating for packaging applica-
tions. There are, however, currently
initiatives to obtain FDA approval for
the use of radcure coatings in direct
food contact.
For steel coil lines a UV curing
system is often incorporated at the
end of galvanising lines whereas, for
aluminium architectural lines, oppor-
tunities may exist for thin functional
TECHNOLOGY
(e.g. scratch resistance) coatings above
the topcoat.
References
[1] H. Leth-Olsen, Filiform Corrosion of
Painted Aluminium Coil Materials, PhD
thesis, NTNU 1996.
[2] K. Nisancioglu, J. H. Nordlien, A. Afseth
and G. M. Scamans, Significance of Ther-
momechanical Processing in Determining
Corrosion Behaviour and Surface Quality
of Aluminium Alloys, 7th International
Conference on Aluminium Alloys their
Physical and Mechanical Properties, 111-
125, 2000.
[3] G. M. Scamans, A. Afseth, G. E. Thomp-
son and X. Zhou, Ultra-fine Grain Sized
Mechanically Alloyed Surface Layers on
Aluminium Alloys, 8th International Con-
ference on Aluminium Alloys, Aluminium
Alloys their Physical and Mechanical
Properties, 1461-1466, 2002.
[4] J. Ball, P. K. F. Limbach, J. D. B. Shar-
man, A New Electrolytic Cleaning Cell. 1st
International Symposium on Aluminium
Surface Science and Technology (ASST
1997), Antwerp, Belgium, May 1997,
pp31-37 (ATB Metallurgie, Brussels, Ed.
H. Terryn).
[5] J. A. Treverton, N. C. Davies, An XPS
study of Chromate Pretreatment of Alu-
minium, Metals Technology ,4, 480-489,
1977.
[6] J. S. Crompton, P. R. Andrews and E.
McAlpine, Characteristics of a Conver-
sion Coating on Aluminium, Surface and
Interface Analysis, vol.13, no.2-3, 160-166,
November 1988.
[7] A. Ruiz Garzon, G. E. Thompson, P.
Skeldon, T. Hashimoto, J. Sander, A. de
Zeeuw and P. Mitchell, Development of
Zirconium-Based Conversion Coatings on
AA3005 Aluminium Alloy, Proceedings
of 4th International Symposium on Alu-
minium Surface Science and Technology
(ASST 2006), Beaune, France, May 2006.
[8] T. Schmidt-Hansberg, P. Schubach,
A Comparative Study of Innovative Alu-
minium Pretreatments, 3rd International
Symposium on Aluminium Surface Sci-
ence and Technology, (ASST 2003), Bonn,
Germany, May 2003, pp9-14 (ATB Metal-
lurgie, Brussels, Ed. H. Terryn).
[9] K. Br, NIR Booster Solutions Pay-
Back Within 12 Months! ECCA 38th Au-
tumn Congress Brussels, 21-23 Novem-
ber 2004.
Author
Dr. Nigel Davies is currently Managing
Director of Innoval Technology Ltd, an
independent light metals technology con-
sultancy based in Banbury, UK. Prior to
this, he had worked for Alcan in a range
of functions including having technical
responsibility for Alcans (now Novelis)
European painted sheet division.
97
 FORSCHUNG
Rhrreibschweien von artungleichen
Aluminiumknet- und -druckgusslegierungen
Sh. Sheikhi, J. F. dos Santos, Geesthacht
Das Rhrreibschweien (Friction
Stir Welding FSW) ist ein innova-
tiver Fertigungsprozess zum Fgen
von Leichtmetallen, besonders
von Aluminiumlegierungen. Die
Herstellung von Aluminiumverbin-
dungen mit konventionellen
Schmelzschweiverfahren erfllt
nicht immer und nicht bei jeder
Legierung die von der Industrie
gestellten Qualittsanforderungen.
Das Rhrreibschweien stellt
eine Alternative zu den Schmelz-
schweiverfahren dar. Dies ist
besonders auf die guten mechani-
schen Eigenschaften der Schwei-
nhte, die Reproduzierbarkeit und
die Robustheit des Verfahrens
zurckzufhren. Im Rahmen die-
ser Arbeit werden artungleiche
Stumpfstoe gleicher Blechdicke
mit den Legierungen AlMg3,
AlMgSi0,5 und GD ALSi10Mg her-
gestellt. Die Blechdicke der einge-
setzten Fgepartner betrgt 2 mm.
Es werden die Gefgeausbildung
als Folge der eingebrachten
Streckenenergie beschrieben und
die mechanischen Eigenschaften
der Schweinhte diskutiert.
Beim FSW-Verfahren handelt es sich
um ein speziell zum Schweien von
a
b
Abb. 1a) Werkzeug fr das Reibrhrschweien; 1b) Prozessablauf beim Schweien
98
Aluminium und Aluminiumlegie-
rungen geeignetes Fgeverfahren.
Friction Stir Welding (FSW) wur-
de von TWI (The Welding Institute,
Cambridge) entwickelt und 1991 pa-
tentiert [1].
Das Reibrhrschweien erfolgt
bei Temperaturen unterhalb des
Schmelzpunktes der Fgepartner. Die
Werkstoffe schmelzen nicht, sondern
werden lediglich plastifiziert und im
Nahtbereich regelrecht ineinander
verrhrt. Da kein Schmelzbad ent-
steht, ist das Verfahren lageunabhn-
gig. Das Reibrhrschweien zeichnet
sich insbesondere durch reprodu-
zierbare und gute Schweinahteigen-
schaften aus. Die Vorteile gegenber
herkmmlichen Schweiverfahren re-
sultieren zum einen aus dem geringen
Wrmeeintrag sowie der einfachen
Prozesskontrolle und -steuerung. Vor-
teile gegenber den herkmmlichen
Schmelzschweiverfahren sind wei-
terhin: ein geringer Verzug, keine
Poren- und Rissbildung und keine
Entmischung der Legierungsbestand-
teile. Eine spezielle Behandlung der
Fgekanten vor dem Schweien ist
nicht notwendig. Es sind weder Zu-
satzwerkstoffe noch Schutzgase er-
forderlich, auch muss kein speziell ge-
schultes Personal eingesetzt werden,
was zu sehr geringen Betriebskosten
fhrt. Beim Reibrhrschweien wird
ein zylinderfrmiges Werkzeug (Abb.
1-a) eingesetzt. Das Werkzeug besteht
aus einem Stift (Pin), der in der Werk-
zeugschulter befestigt wird und na-
hezu verschleifrei funktioniert. Die
modulare Ausfhrung des Werkzeugs
erlaubt die Anpassung.
Zum Schweien wird gem Abb.
1-b das rotierende Werkzeug lang-
sam in den Fgebereich eingebracht.
Infolge der Rotationsbewegung des
Werkzeugs sowie des aufgebrachten
Druckes wird zwischen Schulter und
Blechen Reibungswrme erzeugt,
die zum Plastifizieren des Materials
unter der Schulter fhrt. Nach aus-
reichender Plastifizierung wird das
rotierende Werkzeug unter einer be-
stimmten Vorschubgeschwindigkeit
(Schweigeschwindigkeit) entlang
des zu schweienden Bereiches ge-
fhrt.
Die Rotationsrichtung und die
Translationsbewegung des Werk-
zeuges berlagern sich. Auf der einen
Seite der Fgelinie sind die Bewe-
gungsvektoren gleichgerichtet und
auf der anderen Seite wirken sie ent-
gegengesetzt zueinander. Die Seite
mit gleicher Richtung der Rotations-
und der Translationsbewegung wird
mit Advancing-Seite bezeichnet. Die
Retreating-Seite beschreibt die Seite
mit entgegengesetzter Richtung der
Rotations- und der Translationsbewe-
gung. Das charakteristische Bild einer
mit FSW produzierten Naht ist in Abb.
2 dargestellt.
In der Mitte der Naht liegt der
Nugget oder die Rhrzone mit einer
zwiebelartigen Struktur. Dieser Be-
reich entsteht durch den hohen Ver-
formungsgrad im Bereich des Stiftes
sowie der Reibungstemperatur. Die
Form des Nuggets ist abhngig von
den Schweiparametern. Das Gefge
in diesem Bereich ist feinkrnig ca.
2-5 m [2]. Die zwiebelfrmige Struk-
tur entsteht dabei durch die Rotation
ALUMINIUM 1-2/2007
 FORSCHUNG

Rp0,2, Zugfestigkeit Rm, Bruchdehnung

A der verwendeten Grundwerkstoffe
variiert gem Tabelle 2 sehr. Alle
Schweinhte wurden mit einem
Werkzeug bestehend aus einem
13 mm konkaven Schulter- und einem
5 mm Stiftbereich hergestellt.

Ergebnisse

Abb. 2: Gefge der FSW-Naht Die Entwicklung einer FSW-Verbin-

und den Vorschub des Werkzeuges.
Der thermomechanisch beeinflusste
Bereich schliet sich am Rand des
Nuggets an. Das Material ist in diesem
Bereich aufgrund des Rhreffektes
und des Temperaturfeldes thermisch
beeinflusst und plastisch verformt
[2]. Die Wrmeeinflusszone schliet
an diesem Bereich an. Dieser Bereich
ist nicht deformiert, erfhrt jedoch
aufgrund der Temperatureinwirkung
eine Vernderung des Gefges infol-
ge von Ausscheidungen. Infolge der
unterschiedlichen Bereiche in der
Schweinaht variieren die mecha-
nischen Kennwerte quer zur Naht.
So ist die Festigkeit im Bereich des
Nuggets innerhalb der Schweinaht
am hchsten, in Einzelfllen (5xxx-
Legierungen, die nicht kalt verfestigt
sind) kann eine hhere Festigkeit als
im Grundwerkstoff erreicht werden.
FSW zeichnet sich durch reprodu-
zierbare und gute Schweinahteigen-
schaften aus. Die Vorteile gegenber
herkmmlichen Schweiverfahren
resultieren zum einen aus dem gerin-
Mechanische
Eigenschaften AlMg/5754-O
Rp0,2 [MPa] 120
Rm [MPa] 220
A [%] 26
Vikershrte HV0,2 59
Biegewinkel [] 160
Tabelle 2: Mechanische Eigenschaften der verwendeten Werkstoffe
gen Wrmeeintrag und zum anderen
daraus, dass jegliche Aluminiumle-
gierungen mit diesem Verfahren ge-
schweit werden knnen.
Mit dem Rhrreibschweien sind
smtliche artgleiche und artunglei-
che Aluminiumlegierungen schwei-
bar. Diese knnen in verschiedenen
Nahtkonfigurationen (wie Stumpf-
sto, Stumpfsto/Parallelsto, ber-
lappsto, Parallelsto, T-Ste und
Kehlnaht) hergestellt werden [3].
Material
Im folgenden sind Beispiele fr artun-
gleiche Rhrreibschweinhte darge-
stellt. Die Schweiversuche wurden
mit den folgenden Werkstoffen gem
Tabelle 1 durchgefhrt. Dabei wur-
den artungleiche Stumpfste glei-
cher Blechdicke mit den Legierungen
AlMg3, AlMgSi0,5/6060-T4 und GD
ALSi10Mg hergestellt. Die Blechdi-
cke der eingesetzten Fgepartner
betrgt 2 mm. Die mechanischen
Eigenschaften wie z. B. Dehngrenze
Legierung
AlMgSi0.5/6060-T4 GD AlSi10Mg
90 150
185 288
27 6 schwindigkeiten fhren zu einer Er-
62 88
160 30
dung mit abnehmender Streckenener-
gie bei einer Drehzahl von 2000 min-1,
ist am Beispiel AlMg3 - DGAlSi10Mg
in Abb. 3 dargestellt. Bei dieser Werk-
stoffkombination wurde ein sprder
Aluminiumdruckguss mit einer nicht
aushrtbaren, gewalzten Alumini-
umlegierungen gefgt. Bei kleinen
Vorschben und dementsprechend
groer Wrmeeinbringung zeigt sich
deutlich die Struktur des Nugget. Mit
abnehmender Streckenenergie ver-
schlechtert sich optisch die Durch-
mischung des Kernbereiches und
fhrt zu Fehlern in der Schweinaht.
Typischer Weise sind diese Fehler
auf der Advancing-Seite der Rhrzo-
ne zu finden. Die Streckenenergie qs
[J/mm] wird als Quotient des theore-
tischen Energiestroms q [W] und der
Schweigeschwindigkeit vsch [mm/s]
ermittelt [4].
qs = (4/3 x S x Px Fz x N x rsch) / vsch
[J/mm] (Gleichung 1)
Der Energiestrom q [W] ergibt
sich aus dem Reibungskoeffizienten
P = 0,2, der Schweikraft Fz [N], der
Drehzahl N [s-1] und dem Schulterra-
dius rsch [m]. Der Reibungskoeffizient
verndert sich mit dem Plastifizie-
rungsgrad bzw. mit der Erhhung der
Temperatur [5]. Die Erhhung der
Schweiparameter (Kraft und Dreh-
zahl) fhrt zu einer Erhhung des En-
ergiestroms. Langsamere Schweige-
hhung der Streckenenergie und um-
gekehrt. Es muss betont werden, dass
die Gleichung 1 die Streckenenergie

Zusammensetzung in Gewichts-%
Legierung Si Fe Cu Mn Mg Cr Ni Zn Ti Al
AlMg3/5754-O 0,189 0,301 0,053 0,251 2,66 0,056 --- 0,033 0,033 Rest
AlMgSi0.5/6060-T4 0,3-0,6 0,1-0,3 0,1 0,1 0,35-0,6 0,05 --- 0,15 0,1 Rest
GD AlSi10Mg 9,0-11,0 1,0 1,0 0,001-0,4 0,00-0,5 --- 0,1 0,15 --- Rest

Tab. 1: Chemische Zusammensetzung der verwendeten Werkstoffe

ALUMINIUM 1-2/2007 99
 FORSCHUNG
Abb. 3: Entstehung von Bindefehler in Abhngigkeit von der Streckenenergie
nicht richtig beschreiben kann, da die
Wrmeentwicklung durch die Verfor-
mung des Gefges nicht bercksich-
tigt wird.
Mit optimierten Schweiparame-
tern knnen fehlerfreie Schweinh-
te produziert werden. Der Querschliff
in Abb. 4 stellt eine Stumpfstover-
bindung der Legierungen AlMg3 und
AlMgSi0,5 (von links nach rechts) dar.
Durch die unterschiedliche tzung
der Werkstoffe ist der Materialver-
bund in der Rhrzone zu erkennen.
Die Schweinaht einer rhrreib-
geschweiten Druckgusslegierung
GD AlSi10Mg mit der Legierung
AlMgSi0,5 ist in Abb. 5 und mit der
Legierung AlMg3 in Abb. 6 dargestellt.
Es ist deutlich zu sehen, dass die Ma-
terialpaarung in Abb. 6 zu einer bes-
Abb. 4: Makroschliff FSW-Schweiverbindung
AlMg3/AlMgSi0,5
Abb. 5: Makroschliff FSW-Schweiverbindung
GD AlSi10Mg/AlMgSi0,5
Abb. 6: Makroschliff FSW-Schweiverbindung
GD AlSi10Mg/AlMg3
100
seren Mischung bewegen sie sich zwischen dem spr-
der Fgepartner den Druckguss und dem duktilen
in der Rhrzone Walzblech.
fhrt. Im Zugversuch versagten die Pro-
Der Verlauf ben parallel zur Schweinaht im Be-
des Spannungs- reich des Fgepartners mit der gerin-
Dehnungs-Dia- geren Festigkeit. Die Lage des Bruches
grammes der ist in Abb. 8 abgebildet.
AlMg3/GDAl- Die Bruchdehnung A bezieht sich
Si10Mg-Verbin- auf die Anfangslnge L0 der Proben.
dung ist, stell- Bei einer FSW-Verbindung setzt sich
vertretend fr nun diese Lnge nicht aus einem ho-
die weiteren mogen Stck, sondern aus verschie-
Verbindungen, denen Zonen mit unterschiedlichen
in Abb. 7 dar- Legierungen und Eigenschaften zu-
gelegt. Die Ver- sammen. Daher konzentriert sich die
bindungen er- Dehnung hauptschlich auf einem
reichen somit Bereich innerhalb der Probe und fhrt
eine Zugfestigkeit von Rm = 225 MPa, zu einer relativ niedrigen Bruchdeh-
welche dem Wert des Grundwerk- nung. Die in Tabelle 3 angegebenen
stoffes AlMg3 in etwa entspricht. Werte fr RP0,2, Rm, der Bruchdehnung
Die verbleibenden Proben erreichen A und des Biegewinkels stellen den
beide eine Bruchdehnung von A = 12 Durchschnitt aus mindestens drei art-
%. Mit ihren Materialeigenschaften, gleichen Proben dar.
Abb. 7: Spannungs-Dehnungskurven
b
c
Abb. 8: Bruchlage von geschweiten Zugproben
ALUMINIUM 1-2/2007
 FORSCHUNG

Die Zugfestigkeit der geschweiten schiedlichen Aluminiumlegierungen

Proben erreicht im Verhltnis zum
jeweils schwcheren Fgepartner
gem Tabelle 3 97 % fr die erste
Verbindung, 94 % fr die zweite Ver-
bindung und 100% fr die dritte Ver-
bindung. Die Duktilitt der Schwei-
nhte kann durch den Biegewinkel
ausgedruckt werden. Bei der Werk-
stoffkombination 1 wird der gleiche
Biegewinkel erreicht wie bei den
eingesetzten Grundwerkstoffen. Die
Werkstoffkombinationen 2 und 3 zei-
gen einen deutlichen hheren Biege-
winkel im Vergleich zum Druckguss.
Dies ist zum einen auf die gute Ver-
mischung der Grundwerkstoffe und
zum anderen auf die Reduzierung der
Korngre in der Rhrzone zurck-
zufhren. Die Erhhung der Duktilitt
durch ein feinkrniges Gefge infolge
des Rhrreibschweiens wird in der
Literatur [6, 7] mit unterschiedlichen
Versuchen bewertet.
Aufgrund des Schweivorganges
entsteht eine sehr feinkrnige Struk-
besteht nicht. Im Rahmen dieser Ar-
beit wurde der Einsatz des Verfah-
rens am Beispiel von artungleichen
Mischverbindungen demonstriert
und bewertet.
Es konnte gezeigt werden, dass der
Materialfluss in der Rhrzone sich
abhngig von der Streckenenergie
verhlt. Die Abnahme der Strecken-
energie resultierte aus der Bildung
von Fehlstellen im Materialverbund a
der Rhrzone ein Hinweis auf die
falsche Parameterkombination.
Mit der richtigen Parameterkom-
bination wurden fehlerfreie artunglei-
che Stumpfste mit den Legierungen
AlMg3, AlMgSi0,5 / 6060-T4 und GD
ALSi10Mg hergestellt. Die Zugproben
versagten im jeweils schwcheren
Grundwerkstoff weit entfernt von
der Naht. Aufgrund der feinen Mi-
krostruktur in den Schweinhten
konnte eine Verbesserung der Dukti- b
litt gegenber der des Druckgusses Abb. 9: Gefge der Druckgusslegierung im
festgestellt werden. Grundwerkstoff (a) und in der Rhrzone (b)

tur im Bereich der Rhrzone der Nh-
te, dies kann am besten aus dem Ver-
gleich der Mikrostruktur des Druck-
gusses im Grundwerkstoff und im
Nugget verdeutlicht werden (Abb. 9).
Die Korngre im unbeeinflussten
Grundwerkstoff betrgt 20 bis 30 m.
Aufgrund des Schweiverfahrens ent-
steht ein rekristallisiertes Gefge mit
einer Korngre von etwa 5 m. Dies
fhrt zu einer Verbesserung der Dukti-
litt der Druckgusslegierung. Darber
hinaus knnen Fehler im Druckguss
wie z. B. Poren oder Risse im Bereich
der Rhrzone behoben werden [6].
Somit bietet das Rhrreibschweien
die Mglichkeiten, das Gefge des
Werkstoffes lokal, der Belastung ent-
sprechend, zu verndern.
Zusammenfassung
Das Schweien von Aluminiumlegie-
rungen kann fehlerfrei realisiert wer-
den. Eine Einschrnkung hinsichtlich
der Werkstoffkombination aus unter-
Werkstoffkombinationen RP0,2 [MPa]
AlMg3 / AlMgSi0.5 100
AlMgSi0.5 / GD AlSi10Mg 90
AlMg3 / GD AlSi10Mg 110
Tab. 3: Mechanische Eigenschaften der FSW-Proben
Die Betrachtung des Gefges
verdeutlicht, dass eine Kornfeinung
insbesondere des Gusswerkstoffes
stattgefunden hat. Somit besteht die
Mglichkeit, den Rhrreibprozess
zur gezielten lokalen nderung des
Gefges und als Reparaturverfahren
fr typische Unregelmigkeiten in
Gussbauteilen (wie oberflchennahe
Risse etc.) einzusetzen.
Danksagung
Die Autoren bedanken sich bei C.
Schilling und M. Nchtern fr die
Durchfhrung der Versuche ganz
herzlich.
Literatur
1. W. M. Thomas, D. E. Nicholas, C. J.
Needham: Improvements relating to fric-
tion welding; Patent No. EP 0 615 480 B1;
1994.
2. I. Ballerstein: Feasibility study of fric-
tion stir welding of ship components; Di-
ploma thesis; Technical University Ham-
Rm [MPa] A [%] Biegewinkel []
180 12 160
175 10 75
225 12 75
burg-Harburg; 2000.
3. P. L. Threadgill: Friction stir welding
the state of the art ; TWI Research Re-
port; 1999.
4. O. T. Midling, G. Rorvik: Effect of tool
shoulder material on heat input during
friction stir welding; 1st International
Symposium on Friction Stir Welding 14-
16 June 1999; California, USA; 1999.
5. C. M. Chen, R. Kovacevic: Finite ele-
ment modeling of friction stir welding
- thermal and thermmechanical analysis;
International Journal of Machine Tools
& Manufacture; 2003; Vol. 43, p. 1319-
1326.
6. W. M. Thomas, D. G. Staines, I. M. Nor-
ris, and E. R. Watts: Friction Stir Welding
Process Developments; 12th Interna-
tional Conference on the Joining of Mate-
rials (JOM-12); Helsingor, Denmark; 20-23
March 2005.
7. S. Sheikhi, J. F. dos Santos: Eigenschaften
von rhrreibgeschweiten Aluminium-
Mischverbindungen; Schlsseltechnolo-
gie Leichtmetallguss im Automobilbau,
17./18. November 2005 - Bad Nauheim.
Autoren
Dr. Jorge F. dos Santos leitet die Gruppe
Fgetechnologie am Institut fr Werkstoff-
forschung des GKSS Forschungszentrums
Geesthacht GmbH.
Dr.-Ing. Sharam Sheikhi ist Projektinge-
nieur am Institut fr Werkstoffforschung
des GKSS.

ALUMINIUM 1-2/2007 101

V E R A N S TA LT U N G E N
22nd ASK Metal Forming: Forming the Future
Presenter: Institute of Metal Form-
ing (IBF) and Institute of Ferrous
Metallurgy (IEHK), RWTH Aachen
University, 8 and 9 March 2007.
New materials, forming procedures,
machines and comprehensive simu-
lation and optimisation methods are
the basis for rapid improvements in
the development of the forming tech-
nology. In many cases this leads to in-
creasingly powerful, customised end-
products and cost-effective process
chains. The 22nd ASK Metal Forming
will include contributions from the
scientific and industrial communi-
ties, encompassing a broad spectrum
of topics from the seemingly classic to
state-of-the-art future technologies.
Forging and rolling can open up
new markets and ensure market
The Coatings Summit
5 to 6 February 2007, Vienna, Austria
Top-level speakers from Asia, Amer-
ica and Europe, from global groups
and medium-sized power players, will
share their insight into vital and emerg-
ing issues of the coatings industry.
They will identify trends and discuss
key drivers, be it the changing nature
of sourcing and manufacturing, mar-
ket entry strategies or new regions to
source creativity and innovation.
Further information:
European Coatings Conference
Tel: +49 (0)511 9910-270
esther.schwencke@coatings.de
www.coatings.de
R+T 2007
10. bis 14. Februar 2007, Stuttgart
Themenschwerpunkte der internatio-
nalen Fachmesse in Stuttgart sind der
Rolladen-, Jalousie- und Markisenbau
sowie der Sonnenschutz, Tor- und
Fensterbau. Das Fachpublikum er-
streckt sich auch auf Architekten und
Fachplaner.
Weitere Infos:
Messe Stuttgart
Tel: +49 (0)711 2589-0
info@messe-stuttgart.de
www.messe-stuttgart.de
102
shares by material development,
process simulations and process
monitoring. Moreover, it is possi-
ble to overcome the past limitations
of forming technology by applying
modern developments. For example,
new flexible forming procedures like
strip profile rolling, incremental sheet
forming or flexible ring profile rolling
enable the cost-effective production
of small lot sizes and bad optimised
lightweight products. Miniaturisation
opens up new markets for micro-parts
made of metal. Modern simulation
techniques and material models sup-
port the process planning by predic-
tions of grain structure, part quality
and process capability.
Simultaneously to the lectures,
there will be an exhibition, where in-
terested companies will present prod-
Bauen und Energie
15. bis 18. Februar 2007, Wien
Die internationale Messe fr alle, die
beim Bauen, Renovieren, Modernisie-
ren, und Energie sparen auf Kostenef-
fizienz und Qualitt achten.
Weitere Infos:
Reed Exhibitions Messe Wien
Tel: +43 (0)1 727 20-0
info@messe.at
www.messe.at
3. Landshuter Leichtbau-Colloquium
22. und 23. Februar 2007, Landshut
Das Colloquium zum Thema Leicht-
bau - von der Idee zum Produkt bietet
ein Forum, um ausgesuchte Leichtbau-
lsungen zu prsentieren. Der Leicht-
bau soll dabei ber den gesamten Pro-
duktlebenszyklus von der Idee bis zum
fertigen Produkt und dessen Wieder-
verwertung diskutiert werden.
Weitere Infos:
Fachhochschule Landshut
Tel: +49 (0)871 506 134
info@leichtbau-cluster.de
www.leichtbau-cluster.de
2007 SME Annual Meeting Exhibit
25 to 28 February 2007, Denver, U.S.
The meeting covers a broad range of
topics regarding mineral and metallur-
ucts and services. In the afternoon of
the second day, the participants will
get the facility to attend demonstra-
tions at the constructions of the IBF of
the RWTH Aachen. There is also the
opportunity to visit the IEHK and the
Centre of Metal Construction.
The Colloquium is addressed to all
responsible persons in the steel- and
non-ferrous metal industry dealing
with the production, design, plant
construction, manufacturing, inspec-
tion and applications of innovative
products. All presentations will be
translated simultaneously into Eng-
lish.
Further information:
Dipl.-lng. Marcus Urban
Tel: +49 (0)241 8095927
ask@ ibf.rwth-aachen.de
www. ibf. rwth-aachen .de
gical processing. SME will celebrate its
50 year anniversary.
Further information:
Society for Mining, Metallurgy and Ex-
ploration
Tel: +1(303) 973-9550
meetings@smenet.org
www.smenet.org
TMS 2007 Annual Meeting Exhibition
25 Feb. to 1 March 2007, Orlando, U.S.
More than 140 exhibitors from some
20 countries will present solutions to
technical challenges in a vast array of
areas: e.g. cast shop technology, emerg-
ing materials, environmental manage-
ment, industrial process control and
automation, primary production equi-
ment and services, technology resourc-
es, surface processes.
Further information:
The Minerals, Metals & Materials
Society
Tel: +1(724) 776 9000
mtgserv@tms.org
www.tms.org
7. KBU-Kolloquium: Bergbauliche Ab-
flle und Emissionshandel
1. und 2. Mrz 2007, Aachen
Eine gemeinsame Tagung des Lehr-
und Forschungsgebietes Berg- und
ALUMINIUM 1-2/2007

Umweltrecht der RWTH Aachen und
der GDMB Gesellschaft fr Bergbau,
Metallurgie, Rohstoff- und Umwelt-
technik. Die Themen sind unter an-
derem: Die Anforderungen an die
Verwertung mineralischer Abflle,
die Verordnung mineralische Abflle,
Einsatzmglichkeiten bergbaulicher
Abflle fr Baustoffe, Emissionshan-
delsrecht, NAP II.
Weitere Infos:
GDMB
Tel: +49 (0)5323 937 90
gdmb@dgmb.de
www.gdmb.de
EFB-Kolloquium Blechverarbeitung
06. und 07. Mrz 2007, Fellbach
Das Kolloquium steht unter dem Leit-
thema Neue Wege zum wirtschaft-
lichen Leichtbau Innovative Lsun-
gen zur Blechumformung und mecha-
nischen Fgetechnik. In den einzelnen
Sektionen werden die aktuellen Frage-
stellungen zu hchstfesten Sthlen und
anderen Werkstoffen sowie zu Verfah-
ren in der Fgetechnik und Simulation
im Leichtbau aufgegriffen.
Weitere Infos:
Europische Forschungsgesellschaft
fr Blechverarbeitung
Tel: +49 (0)511 97175-0
info@efb.de
www.efb.de
metall Mnchen
07 to 10 March 2007, Munich, Germany
European specialist trade fair for metal-
working in industry and trade. The fair
will present solutions for areas such as
tool machines, precision tools, com-
ponents, component modules and ac-
cessories, manufacturing and process
automation, measuring technology and
quality assurance.
Further information:
Gesellschaft fr Handwerksmessen
Tel: +49 (0)89 949 55-0
messe@ghm.de
www.ghm.de
Metal Build 2007
12 to 15 March 2007, Moscow, Russia
Metal Build 2007 is the fifth anniver-
sary exhibition of metal in construc-
tion and architecture, covering all
questions from materials for metal
constructions to their processings up
to finished products.
ALUMINIUM 1-2/2007
EVENTS
Fortbildung
Einfhrung in die Technologie des Aluminiums, 12.-14.02.2007, Aachen
DGM Deutsche Gesellschaft fr Materialkunde, Tel.: 069 75306 757,
E-Mail: np@dgm.de, www.dgm.de
Die neue Gefahrstoffverordnung in der Praxis, 13.-14.02.2007, Stuttgart
VDI Wissensforum, Tel.: 0211 6214 201,
E-Mail: wissensforum@vdi.de, www.vdi-wissensforum.de
Neue Werkstoffnormung und neue Werkstoffbezeichnungen fr
metallische Werkstoffe in Europa, 15.02.2007, Essen
Haus der Technik, Tel.: 0201 1803 344,
E-Mail: information@hdt-essen.de, www.hdt-essen.de
Betriebswirtschaftliche Grundlagen fr technische Fhrungskrfte
22.-23.02.2007, Mainz
Ostbayer. Technologie-Transfer-Institut (Otti), Tel.: 0941 29688 21,
E-Mail: margit.zierl@otti.de, www.otti.de
Der Sicherheitsbeauftragte, 26.-27. Februar 2007, Hannover
TV Nord Akademie, Tel: 0511 986 1910,
E-Mail: bcramer@tuev-nord.de, www.tuevnordakademie.de
Systematische Beurteilung technischer Schadensflle
11.-16.03.2007, Ermatingen, CH
DGM Deutsche Gesellschaft fr Materialkunde, Tel.: 069 75306 757,
E-Mail: np@dgm.de, www.dgm.de
Einfhrung in die Metallkunde fr Ingenieure und Techniker,
13.-16.03.2007, Darmstadt
DGM Deutsche Gesellschaft fr Materialkunde, Tel.: 069 75306 757,
E-Mail: np@dgm.de, www.dgm.de
Trends in der Nutzfahrzeugindustrie, 20.-21.03.2007, Mnchen
Euroforum, Tel.: 0211 9686 3611,
E-Mail: theresia.strehler@euroforum.com, www.euroforum.de
Further information: service@dfo-online.de
Tel: +7 (495) 956-48-22 www.dfo-online.de
metalbuild@m-expo.ru
www.metal-build.ru Russia Aluminium Casting Conference
27 to 29 March 2007, Moscow, Russia
DFO-Leichtmetall-Tagung The conference is organised by Alusil-
20. und 21. Mrz 2007, Neuss MVT under the assistance of Russian
Thema der Tagung: Die Oberflchen- Association of Foundrymen and Alu-
behandlung von Leichtmetallen. Im minium Extruders Association. Sub-
Vordergrund stehen die Vorbehand- jects are: markets, applications and
lung, anodische Oxidation und PVD- research, melt preparation, ingot and
/Plasmabeschichtung von Aluminium. continuous casting, manufacture of
Es werden moderne Korrosions- und castings, environment and safety. The
Verschleischutzsysteme vorgestellt. conference will be supplemented by
Weitere Tagungsthemen betreffen den the exhibition of state-of-the-art cast-
Werkstoff Magnesium. ing equipment and technologies.
Weitere Infos: Further information:
Deutsche Forschungsgesellschaft fr Tel: +7 (495) 785-2005
Oberflchenbehandlung e. V. (DFO) main@alusil.ru
Tel: +49 (0)2131 40 811 10 www.alusil.net
103
U M W E LT P R E I S
BDI-Umweltpreiswettbewerb 2007/08
Umweltfreundlichkeit siegt
Der Bundesverband der deutschen
Industrie (BDI) hat den Umwelt-
preiswettbewerb fr die Industrie
2007/08 erneut ausgeschrieben.
Der Wettbewerb ist Teil des euro-
pischen Umweltpreises der EU-
Kommission. Die Sieger der natio-
nalen Wettbewerbe nehmen damit
auch auf europischer Ebene teil.
Insgesamt benennt der BDI-Umwelt-
wettbewerb fnf Preiskategorien.
Preiskategorien
Umweltfreundliche Technologien
Umweltfreundliche Produkte
Umweltorientierte Unternehmens-
fhrung
Umweltschutz-Technologietrans-
fer in Entwicklungs- und Schwel-
lenlnder und Staaten Osteuropas
Kreislaufwirtschaft, Recycling und
Abfallmanagement.
ber die nationalen Preistrger und
die Benennungen zum europischen
Wettbewerb entscheidet eine Jury
aus namhaften Persnlichkeiten aus
Wirtschaft, Wissenschaft, Politik und
Umweltorganisationen. Vorgeschal-
tet ist eine fachliche Prfung durch
das Fraunhofer-Institut fr System-
und Innovationsforschung (ISI) in
Karlsruhe. Der Beurteilung der einge-
henden Bewerbungen liegen neben
den allgemeinen Kriterien Umweltent-
lastung, Ressourcenschonung, wirt-
schaftlicher sowie gesellschaftlicher
Nutzen (Nachhaltigkeit) und Inno-
vationsleistung folgende spezifische
Anforderungen in den einzelnen Preis-
kategorien zugrunde:
Umweltfreundliche Technologien
Entwicklung innovativer Verfah-
ren zur Verringerung von Umwelt
belastungen an der Quelle ihres
Entstehens sowie zur Schonung
von Ressourcen.
Erfllung von Umweltstandards
und Umweltentlastungen ber
gesetzliche Vorgaben hinaus.
Vorrang integrierter Prozesse vor
104
end-of-pipe-Lsungen sowie von
Verfahren und Technologien mit
grerer Anwendungsbreite.
Umweltvertrgliche Produkte
Umweltentlastung durch inno-
vative, koeffiziente Produkte
und Dienstleistungen.
Einbeziehung von Ressourcen-
schonung, Energieeffizienz, Recyc-
ling- und Entsorgungsfreundlich-
keit bei der Produktentwicklung
und -gestaltung.
Besondere Bercksichtigung neu-
er Produkte, die bereits am Markt
vorhandene Gter verbessern
bzw. ersetzen und zumindest als
Prototyp vorliegen.
Umweltorientierte
Unternehmensfhrung
Entwicklung einer integrierten
umweltorientierten Unternehmens-
politik, z. B. in Form ganzheitlicher
Umweltschutzkonzepte oder Um-
weltleitlinien.
Art und Grad der Einbeziehung der
Belegschaft in das Unternehmens-
konzept, beispielsweise durch Aus-
und Weiterbildung in Umweltfra-
gen.
Kommunikation mit externen
Zielgruppen.
bernahme von Produktverant-
wortung, z. B. durch Rcknahme-
und Recyclinggarantien.
Umweltschutz-Technologie-
transfer
Diese Kategorie bezieht Technologien
und Produkte wie auch das Umwelt-
schutzmanagement ein. Dabei sind
folgende Kriterien wichtig:
Beispielhafte Zusammenarbeit mit
einem privaten Partner oder einer
ffentlichen Einrichtung im Sinne
einer langfristig tragfhigen Ent-
wicklung.
Lsung eines spezifischen regio-
nalen Umweltproblems unter Be-
rcksichtigung der speziellen An-
forderungen sowie der vorhan-
denen Ressourcen und Fhig-
keiten in diesen Lndern.
Eignung zur weiteren Verbreitung
und knftigen Weiterentwicklung.
Kreislaufwirtschaft, Recycling
und Abfallmanagement
Entwicklung von hochwertigen-
Recyclingmanahmen (produkti-
onsintegrierte Verfahren werden
unter der Kategorie Umwelt-
freundliche Technologien erfasst).
Innovative und effiziente Systeme
zur Sammlung, Verwertung und
zum Wiedereinsatz von Material,
Komponenten und Produkten.
Vermarktung und Wiederverwen-
dung der rezyklierten Materialien
und Produkte.
Ressourcenschonendes und kosten-
effizientes Abfallmanagement.
Teilnahmebedingungen
Am BDI-Wettbewerb knnen Unter-
nehmen und Organisationen aus der
Industrie teilnehmen. Institutionen,
die nicht dem industriellen Bereich
angehren, sind teilnahmeberechtigt,
wenn ihr Projekt in Zusammenarbeit
mit der Industrie entwickelt wurde
und bereits industrielle Anwendung
gefunden hat. Ferner sollten die Pro-
jekte die Ausrichtung auf eine nach-
haltige Entwicklung erkennen lassen,
ber gesetzliche Vorschriften und
Auflagen hinausgehen und sich ent-
weder in operationaler Phase oder
praktizierter Anwendung befinden.
Die Bewerbungsunterlagen zur Teil-
nahme am BDI-Umweltpreiswett-
bewerb fr die deutsche Industrie
2005/06 sind bis sptestens 15. Juni
2007 einzureichen. Die Bekanntgabe
der nationalen Preistrger und die
Verleihung der ideellen Auszeichnun-
gen erfolgen im Rahmen der BDI-
Jahrestagung voraussichtlich im Juni
2008 in Berlin mit einer begleitenden
Ausstellung fr die Preistrger. Die
detaillierten Bewerbungsformalitten
sind auf der Homepage des BDI abruf-
bar. N
ALUMINIUM 1-2/2007
 NEW BOOKS

Virtual Fabrication of Aluminium Products

This book contains the results of a ma-
jor project of the European aluminium
industries and their academic part-
ners on virtual fabrication. Its three
chapters give an overview over:
1. The production, processing and
quality details of semi-finished prod-
ucts (sheet and extrusions) of some
typical conventional wrought alu-
minium alloys and products.
2. The fundamental physical process-
es and recent modelling approaches
of casting, deformation and annealing
processes and microstructures.
3. Their integration and application
in through process simulations of
plant production.
Virtual fabrication defines a new
tool to simulate industrial processes
with integrated models that can pre-
dict related properties and applied to
many purposes, such as:
Improvement of industrial produc-
tion processes and product quality
Improvement of research and de-
velopment quality for process and
product optimization
Design of microstructural states
and resulting specific material prop-
erties
Design most effective and efficient
fabrication and processing routes
Reduce significantly the number
of expensive test runs in productive
plants
Reduce cost and time to market of
new products and processes
Standardize aluminium alloys for
application and to enhance recycla-
bility.
The targeted audience groups are:
industrial production engineers
working on fabrication and process-
ing sites Virtual Fabrication of Aluminium
engineers dealing with product Products, Jrgen Hirsch (Editor)
development and aluminium appli- Hardcover, 406 pages,
cations October 2006
scientists and students working 85.00 / 127.50
in academic and industrial research ISBN: 3-527-31363-X
laboratories.

Umschlsselung DIN zu EN
Europische Aluminiumwerkstoffe
Der europische Binnenmarkt be-
ntigt gemeinsame Normen, die die
Einschrnkungen fr den freien Wa-
renverkehr abbauen helfen. Diese
europische Normung hat auch mit
Blick auf den Werkstoff Aluminium
zu groen Vernderungen gefhrt. In
relativ kurzer Zeit mussten die nati-
onalen Normen durch europische
Normen ersetzt werden, in denen Be-
zeichnungssysteme und Zustandsbe-
zeichnungen fr Werkstoff gendert
wurden.
Um dem Anwender die Umschls-
selung alt/neu fr Aluminium und
seine Legierungen zu erleichtern,
sollte ein einfach zu handhabendes
Hilfsmittel erarbeitet werden. Damit
war der Startschuss fr das Beuth-Po-
cket gefallen.
Die lange Zeit der Erstellung ver-
deutlicht, wie viel Arbeit in dem
handlichen, kleinformatigen Nach-
schlagewerk steckt. Es durchdringt
das Dickicht und ermglicht einen
schnellen Zugriff auf oft mhsam zu-
sammengesuchte Fakten: Das Nach-
schlagewerk bringt Transparenz in
die Flle der Norm-Dokumente. Es
klrt die Bedeutung von Krzeln und
Kennzeichen, vermittelt wichtige In-
formationen fr den betrieblichen
Alltag und verweist nicht zuletzt auf
die gngigen Normen.
Herausgekommen ist das Beuth
Pocket Europische Aluminium-
werkstoffe, das in 1. Auflage 2006
zweisprachig deutsch/englisch er-
schienen ist.
Beuth Pocket
H.-W. Wenglorz, Europische Alu-
miniumwerkstoffe / European Alu-
minium Materials
1. Aufl. 2006. 294 S. 21 x 10,5 cm.
Brosch. 29,80 Euro.
ISBN 978-3-410-16287-2
Beuth Verlag GmbH
Bei zerstrungsfreien Prfungen (ZfP)
wird verstrkt auf die Kombination ver-
schiedener Verfahren gesetzt, um die
Sicherheit unserer technischen Umgebung
zu erhhen. Sowohl fr kombinierte
Methoden wie auch fr Einzelprfungen
stellen zwei DIN-Taschenbcher (TB) das
normentechnische Knowhow zur Verf-
gung. DIN-TB 56 Materialprfnormen
fr metallische Werkstoffe 2 enthlt die
Normen und Norm-Entwrfe fr die Vo-
lumenverfahren der ZfP. Ergnzend dazu
ist DIN-TB 370 Materialprfnormen fr
metallische Werkstoffe 4 erschienen, das
die Normen zu Oberflchenverfahren und
zu anderen ZfP-Verfahren umfasst.
DIN-TB 56, Materialprfnormen fr me-
tallische Werkstoffe 2. 7. Aufl. 2006. 640
S. A5. Brosch. 125,30 Euro. ISBN 978-3-
410-16300-8. Beuth-Verlag GmbH
DIN-TB 370, Materialprfnormen fr
metallische Werkstoffe 4. 2006. 560 S.
A5. Brosch. 106,90 Euro. ISBN 978-3-410-
16313-8., Beuth Verlag GmbH

ALUMINIUM 1-2/2007 105

FIRMENSCHRIFTEN
SECO/Warwick
Aluminium Annealing Furnaces
SECO/Warwick provides custom-
engineered aluminium coil and foil
annealing furnaces with capacities
ranging from single coil modular fur-
naces to multi-zone furnaces with
tight zone control. The company
continues to develop technologies to
improve equipment performance and
efficiency. Two significant improve-
ments for coil and foil processing
include:
Messerfabrik Neuenkamp
Neuer Schneidtechnik-Katalog
Die Messerfabrik Neuenkamp GmbH,
ein Mitglied der internationalen
Dienes-Gruppe, bietet eine breite Pa-
lette von Serviceleistungen rund um
die Schneidtechnik. Zielgruppe ist die
verarbeitende Industrie von Stahl und
NE-Metallen.
Ein neuer Produktkatalog gibt ei-
nen berblick ber das Produkt- und
Serviceprogramm, angefangen bei
Rollscherenmessern ber Distanz-
und Druckverteilungsringe, Sepa-
Schco International
Nachhaltigkeitsbericht SustainIng
Effiziente Lsungen und nachhaltige
Produkte, die hchste Ansprche hin-
sichtlich Komfort und Design erfllen,
mssen kein Widerspruch sein. In der
Natur gibt es zahlreiche Beispiele fr
den perfekten Umgang mit Energie
und Material. Vor diesem Hintergrund
beschftigt sich der aktuelle Schco-
Nachhaltigkeitsbericht SustainIng
mit natrlichen Anstzen fr die zu-
kunftsorientierte Gebudehlle. Die
68-seitige Broschre richtet sich vor
allem an Investoren und Architekten.
Sie informiert ber den nachhaltigen
Umgang mit der Umwelt sowie dar-
106
O Mass flow design to protect load
surfaces that are vulnerable to dam-
age during high atmosphere flow.
O Vortex flow jet heating that re-
duces cycle time by taking advantage
of the high heat transfer produced
through convection heating.
The updated brochure is available
online at www.secowarwick.com or
via e-mail (info@secowarwick.com)
for a print copy.
rierwerkzeuge, komplette Schneide-
einheiten bis hin zu Messertrger-
systemen und zur Poliermaschine.
Die abgebildeten Modelle stehen
beispielhaft fr eine Vielzahl indivi-
dueller Konfigurationen, die auf spe-
zielle Kundenanforderungen entwi-
ckelt werden.
Der Katalog ist in deutscher und
englischer Sprache erhltlich und
kann unter info@neuenkamp.de ange-
fordert werden.
ber, wie sich Gebudehllen an die
weltweit unterschiedlichen Klima-
verhltnisse anpassen lassen. Auer-
dem prsentiert der Bericht berra-
schende Analogien aus der Welt der
Bionik. SustainIng beschreibt nicht
allein mgliche Zukunftsszenarien,
sondern zeigt auch vorhandene L-
sungsmglichkeiten auf. Prominente
Wissenschaftler wie Ernst Ullrich von
Weizscker kommen zu Wort.
Die Broschre liegt in deutscher
und englischer Sprache vor und kann
unter www.schueco.de/architekten
angefordert werden.
ALUMINIUM 1-2/2007

Schuitema, H.
Heavy duty Magnesium. Entwicklung und Druckguss-Pro-
duktion eines 6-Zylinder Magnesium Bedplate
Druckgusspraxis 6/2006, S. 243-246
Nach den neuen EU-Vorschriften, die ab 2008 die Grenzwerte
fr Schadstoffe weiter reduzieren, drfen Pkw nicht mehr als
140 g/km CO2 ausstoen. Dies erfordert weitere Anstrengungen
zur Gewichtsminderung: durch verbesserte Effizienz der Ver-
brennung (innermotorische Manahmen), Reduzierung der
Antriebsverluste im Antriebsstrang, aerodynamische Feinar-
beit und Gewichtsoptimierung durch die Verwendung leichter
Werkstoffe. Ein sddeutscher OEM hat sich fr die Verwendung
von mehr Magnesium entschieden, um das Gewicht des Motors
zu reduzieren. Ein weiterer Aspekt ist die Verbesserung der
Gewichtsverteilung (geringere Belastung der Vorderachse), was
zum dynamischeren Fahrverhalten beitrgt. Die Verwendung
von Magnesium in einer Grenordnung von 20 kg gilt bis jetzt
als einzigartig im modernen Motorenbau. In der Vergangenheit
gab es keine geeigneten Legierungen, die die geforderten Werte
fr mechanische Festigkeit und Kriechverhalten bei hoher ther-
mischer und dynamischer Belastung aufweisen. 3 Bild.
ALUMINIUM 1/2 (2007) Werkstoffeigenschaften
Sequeria, W., Kind, R., Andersen, S., Greeless, G.
Voraussage und Validierung von Verformungen und Eigen-
spannungen in einem Aluminiumdruckgussteil mit Betrach-
tung der fr den Druckgieproze relevanten Parameter
Druckgusspraxis 6/2006, S. 235-242
Das Druckgieverfahren bietet eine exzellente Dimensions-
genauigkeit bei der Herstellung dnnwandiger NE-Gussteile.
Trotzdem treten whrend der Produktion an manchen Guss-
teilen Mahaltigkeitsprobleme auf. Die Tatsache, dass der Form-
hohlraum innerhalb der notwendigen Toleranzen liegt, und das
unregelmige Auftreten der Fehler machen die Suche nach
der Ursache des Problems schwierig. Es ist nicht sinnvoll, die
Belastungsanalyse eines Teils durchzufhren, wenn die sich
whrend des Gieprozesses entwickelnden Eigenspannungen
unbekannt sind. Schwankende Temperaturverteilungen im
Gussteil sind beim Druckgieen hauptschlich durch Wand-
strkenbergnge sowie durch die Anordnung von Khlele-
menten und durch die Formsprheinrichtung begrndet. Nach
der Entnahme aus der Form erfhrt das Teil eine thermische
Behandlung, die von der Abkhlung auf Raumtemperatur an
ruhender Luft bis zur Abschreckung in einem Khlmedium rei-
chen kann. Die Abkhlung fhrt zu Verformungen und Eigen-
spannungen im Gussteil eine der Hauptursachen fr Dimen-
sionsabweichungen im Druckgussteil. Der Artikel diskutiert
die Verformung eines Sicherheitsbauteiles aus Aluminium, die
mittels computergesttzter Verifizierung ermittelt wurde. Die
Ergebnisse werden mit den Resultaten verglichen, die aus der
Anwendung eines Prozessoptimierungstools fr die Abkhlung
von Druckgussteilen von der Formentnahme auf Raumtempera-
tur erhalten wurden. Die Ausbildung von Eigenspannungen und
ihre praktische Bedeutung werden diskutiert. 13 Bild., 9 Que.
ALUMINIUM 1/2 (2007) Formguss
R. P. Pawlek
Dramatic changes in primary aluminium smelting between
1984 and 2005
ALUMINIUM 82 (2006) 12, p. 1206 pp.
Although still using basically century-old technology, the pri-
mary aluminium industry has again doubled in capacity dur-
ing the last twenty years. This is a dramatic increase, even if
the 1984 figures for several of then communist economies are
uncertain. On a macro-economic scale, this industry has been
ALUMINIUM 1-2/2007
LITERATURE SERVICE
transformed more than most by global forces: by the rise of
market economies in China and the former Soviet republics,
and by rising energy costs. In the next twenty years, even with
practically inexhaustible ores, primary aluminium capacity will
be overtaken by recycled aluminium due to energy costs. 6 im-
ages, 2 Tab.
ALUMINIUM 1/2 (2007) Aluminium-Industrie
B. Rieth
Coil Coating weltweit ein Wachstumsmarkt
ALUMINIUM 82 (2006) 12, p. 1170 pp.
Finish first fabricate later unter diesem Slogan wird das
Coil Coating zunehmend als eine kostengnstige Alternative
zur konventionellen Stcklackierung eingesetzt. Organische
Beschichtungslinien vereinen chemische, thermische und
mechanische Prozesse und bieten den Anwendern ein breites
Spektrum an Funktions-, Farb- und Dekorvarianten. Nachfol-
gend soll losgelst von den technischen Details ein ber-
blick ber Mrkte, Anlagentechnik und die Akteure gegeben
werden. 11 Bild.
ALUMINIUM 1/2 (2007) Oberflchenbehandlung
Anon.
Die deutsche Gieereiindustrie eine Branche mit Perspek-
tiven
ALUMINIUM 82 (2006) 12, p. 1163 pp.
Deutschland zhlt heute weltweit zu den fhrenden Gieerei-
nationen. Hinter den bevlkerungsreichen Lndern China, USA,
Russland und Japan steht Deutschland an fnfter Stelle in der
Welt. In Europa ist die deutsche Gieereibranche seit Jahren mit
Abstand fhrend. Wie lsst sich dieser Erfolg angesichts der all-
gemein beklagten Standortnachteile in Deutschland erklren?
Dieser Frage geht der Bericht nach. Fr 2006 ist die Gieerei-
branche optimistisch, das hohe Rekordniveau aus dem Vorjahr
zumindest halten zu knnen. Diese Zuversicht wird durch den
Verlauf des ersten Halbjahres 2006 besttigt. 4 Bild.
ALUMINIUM 1/2 (2007) Formguss
Kraynik, A. M.
The Structure of Random Foam
Advanced Engineering Materials 2006, 8, No. 9, S. 900-906
Surface Evolver models of soap foam with a wide range of
cell-size distributions are used to investigate random cellular
morphology. Geometric properties of foams and foam cells are
analyzed. A simple accurate theory relates the total surface area
of foam to the cell-size distribution. The total surface area is
approximately equal to the total edge length when both quanti-
ties are scaled by average cell volume. Voronoi structures are
significantly different from foams, which raises questions over
their use for predicting structure-property relationships. 22 im-
ages, 13 sources.
ALUMINIUM 1/2 (2007) Werkstoffe, Metallkunde
McElwain, D.L.S., Roberts, A.P., Wilkins, A. H.
Yield Functions for Porous Materials with Cubic Symmetry
Using Different Definitions of Yield
Advanced Engineering Materials, 2006, 8, No. 9, S. 870-876
Plastic yield criteria for porous ductile materials are explored
numerically using the finite-element technique. The cases of
107
LITERATURSERVICE
spherical voids arranged in simple cubic, body-centred cubic
and face-centred cubic arrays are investigated with void volume
fractions ranging from 2 % through to the percolation limit (over
90%). Arbitrary triaxial macroscopic stress states and two defi-
nitions of yield are explored. The numerical data demonstrates
that the yield criteria depend linearly on the determinant of
the macroscopic stress tensor for the case of simple-cubic and
body-centred cubic arrays in contrast to the famous Gurson-
Tvergaard-Needleman (GTN) formula while there is no such
dependence for face-centred cubic arrays within the accuracy
of the finite-element discretisation. The data are well fit by a
simple extension of the GTN formula which is valid for all void
volume fractions, with yield-function convexity constraining
the form of the extension in terms of parameters in the original
formula. Simple cubic structures are more resistant to shear,
while body-centred and face-centred structures are more resist-
ant to hydrostatic pressure. The two yield surfaces correspond-
ing to the two definitions of yield are not related by a simple
scaling.10 images, 21 sources.
ALUMINIUM 1/2 (2007) Werkstoffe, Metallkunde
Shashikala, A.R., Rani, R.U., Sharma, A.. K., Mayanna, S.M.,
Untersuchungen zur selektiven Schwarzverchromung auf
Aluminiumlegierungen fr Solaranwendungen / Studies on
solar selective black chrome plating on aluminium alloys
Galvanotechnik 10/2006, S. 2387-2400
Selektive Solarbeschichtungen absorbieren die Sonneneinstrah-
lung und wandeln sie in Wrmeenergie fr den Hausgebrauch
und industrielle Anwendungen um. Die Schwarzverchromung
wird hufig aufgrund ihrer haltbaren, nicht reflektierenden
Oberflche und ihrer bestndigen optischen Eigenschaften
fr Automobile, Phototechnik, Solarkollektoren und optische
Gerte verwendet. Schwarzchromschichten werden auf ver-
schiedene Werkstoffe wie Kupfer oder Stahl abgeschieden.
Trotz neuer Entwicklungen werden zur Herstellung dnner
Schichten Chrom(VI)elektrolyte eingesetzt. In der vorliegenden
Studie wird die Auswirkung verschiedener Unterschichten
(cyanidisches/nicht cyanidisches Kupfer, galvanisches und
stromloses Nickel) auf die Stabilitt und solare Selektivitt von
Schwarzchromschichten auf Aluminiumlegierungen unter-
sucht. 8 Bild., 23 Que. Beitrag in dt. u. engl. Sprache).
ALUMINIUM 1/2 (2007) Oberflchenbehandlung
Stratemeier, S., Senk, D., Grosse, A., Kurth, B.
Eigenschaften von mechanisch hergestelltem Desoxidations-
aluminium
stahl und eisen 126 (2006) Nr. 11, S. 45-55
Im Jahr 2004 wurden in der deutschen Stahlindustrie rund 76.000
t Aluminium verbraucht. Dieses sog. Desoxidationsaluminium
wird in der Stahlmetallurgie als Granalien und Einteilern ein-
gesetzt, die aus Aluminiumschrotten umgeschmolzen werden.
Eine mgliche Alternative zu thermisch hergestelltem Desoxida-
tionsaluminium ist die Verwendung von sauberem granulierten
Al-Schrott. Der Beitrag untersucht die Eignung von mechanisch
hergestelltem Desoxidationsaluminium aus Schrotten fr den
Einsatz in der Stahlmetallurgie. 10 Bild, 5 Que.
ALUMINIUM 1/2 (2007) Gewinnung
Fr Schrifttum zum Thema Aluminium ist der Gesamtverband der Aluminiumindustrie e.V. (GDA)
der kompetente Ansprechpartner. Die hier referierten Beitrge reprsentieren lediglich einen Aus-
schnitt aus dem umfassenden aktuellen Bestand der GDA-Bibliothek.
Die von der Aluminium-Zentrale seit den dreiiger Jahren kontinuierlich aufgebaute Fach-Bibliothek
wird duch den GDA weitergefhrt, ausgebaut und auf die neuen Medien umgestellt. Sie steht allen
Interessenten offen.
Ansprechpartner ist Dr. Karsten Hein, E-Mail: karsten.hein@aluinfo.de
108
Nogowizin, B.
Geometrische Gestaltung der Gielufe fr Druckgussstcke
Druckgusspraxis 6/2006, S. 247-253
Die Ausschnitttechnik erstreckt sich nicht nur auf den Anschnitt,
sondern auch auf die Gestaltung und die Anordnung der Gie-
lufe, der berlufe und der Entlftung. Der Artikel thematisiert
die Darstellung der geometrischen Gestaltung der Elemente und
ihre Berechnungen fr die Gielauf-Anschnittsysteme, die zur
Entwicklung der erforderlichen computergesttzten Entwurfs-
programme angewandt werden knnen. Es ist nicht das Ziel,
wie ein Gielaufanschnittsystem fr ein bestimmtes Gussstck
zu konstruieren sei, vielmehr wird die Aufmerksamkeit auf die
verschiedenen Einflussgren bei der Gestaltung von Gielu-
fen gelenkt. 7 Bild., 5 Que.
ALUMINIUM 1/2 (2007) Formguss
Pidvysotskyy, V., Matuszyk, P.J., Bloching, H.
Analysis of the Influence of the Specimen Shape on the
Zone of Homogeneous Stress in Tensile Test / Untersuchung
des Einflusses der Probenform im Bereich homogener Span-
nungen beim Zugversuch (Beitrag in engl. Sprache)
MP Materialprfung 2006, 10, S. 498-503
Im vorliegenden Beitrag werden die Ergebnisse aus Unter-
suchungen zum Einfluss der Probengeometrie und der Eins-
pannlnge auf die homogene Dehnung in der Originalprflnge
vorgestellt. Alle Versuche wurden mit einem austenitischen
Stahl 316 L und bei verschiedenen Querschnitten der Flach-
proben durchgefhrt. Die Berechnungen des Verformungsproz-
esses wurden mittels der Finite-Elemente-Methode unter Nut-
zung des Programms Abaqus/Explicit ausgefhrt. Es werden die
Korrelation zwischen der Dehnungsverteilung in den Proben
und verschiedenen Parametern, wie zum Beispiel dem ber-
gangsradius und der Einspannlnge, beleuchtet. 9 Bild., 9 Que.
ALUMINIUM 1/2 (2007) Werkstoffeigenschaften
Haberkorn, G., Blmcke, E.W., Thoma, K.
Durchgngige Betrachtung einer Stanznietverbindung mit
Fokus auf dynamische Belastungen
MP Materialprfung 2006, 10, S. 486-492
Im Zuge des Leichtbaus von Fahrzeugkarosserien kommen
neben einer Vielzahl von Materialien auch zahlreiche unter-
schiedliche Fgetechniken zur Anwendung. Um diese in der nu-
merischen Berechnung zu bercksichtigen, sind umfangreiche
Kenntnisse der Phnomenologie der Verbindung einschlielich
des Versagens notwendig. Es wird eine Mglichkeit der Un-
tersuchung von mechanischen Verbindungen am Beispiel der
Stanznietverbindung aufgezeigt. Dies umfasst die Kombination
von Versuchen und der numerischen Simulation, welche bei
der Prozesssimulation beginnt und ber ein Detailmodell hin
zum abstrahierten Simulationsmodell fr die Gesamtfahrzeug-
berechnung fhrt. Erste Ergebnisse werden vorgestellt und auf
ihre Relevanz im Kontext einer Gesamtfahrzeug-Crashsimula-
tion hin bewertet. 11 Bild., 8 Que.
ALUMINIUM 1/2 (2007) Verbinden
ALUMINIUM 1-2/2007

Patentblatt November 2006
Al-Legierung fr lithographisches Blech.
Alcan International Ltd., Montreal, Que-
bec, CA. (C22C 21/00, OS 102 42 018,
AT 11.09.2002)
Al-Cu-Mg-Ag-Mn-Legierung fr Bauan-
wendungen, die hohe Festigkeit und
hohe Duktilitt erfordern. Alcan Rolled
Products Ravenswood LLC, Ravens-
wood, W.Va., US; Alcan Rhenalu, Paris,
FR. (C22C 21/12, EPA 1 641 952, EP-AT
26.05.2004)
Verfahren zur Herstellung von Al-Mg-
Si-Legierung mit hervorragender Bake-
Hardenability und Falzbarkeit. Nippon
Light Metal Co. Ltd., Tokio/Tokyo, JP.
(C22F 1/05, EPA 1 702 995, EP-AT
13.12.2004)
Zn-Al-Eutektoid-Feuerverzinkung von
nicht rostendem Stahl. University of Cin-
cinnati, Cincinatti, Ohio, US. (C23C 2/06,
1 709 21, EP-AT 21.01.2005)
Kupfer enthaltender, mehrfdiger
Nb3Al-Supraleitungsdraht und Ver-
fahren zu dessen Herstellung. Japan,
vertreten durch den Generaldirektor des
Nationalen Metallforschungsinstitutes,
Tsukuba, Ibaraki, JP. (H01B 12/10, PS
100 55 628, AT 09.11.2000)
Herstellungsverfahren fr einen ultrafei-
nen Multifilament-Supraleiterdraht aus
Nb3(Al, Ge) oder Nb3(Al, Si). JAPAN as
represented by NATIONAL RESEARCH
INSTITUTE FOR METALS, Tsukuba,
JP. (H01L 39/24, EP 1 058 321, EP-AT
05.06.2000)
Zeolithkatalysator, Trger auf Basis von
Silizium-Aluminium-Matrix und Zeolith
und Verfahren zum Hydrocracken von
Kohlenwasserstoffchargen. Institut Fran-
ais du Ptrole, Rueil-Malmaison, Hauts-
de-Seine, FR. (B01J 29/08, EPA 1 711 260,
EP-AT 16.12.2004)
Kontinuierlich graviertes, laminiertes
Aluminium und dessen Benutzung in
Paneelen. Lloveras Calvo, Juan, San Feliu
de Codinas, ES. (B21B 15/00, EPA 1 710
026, EP-AT 06.04.2005)
Verfahren zur Herstellung von Alumini-
um-Kokillenguss mit dem Zweck eine Ge-
fgeverbesserung bei den gegossenen
Teilen zu erreichen. Fuchs, Hermann,
57520 Steinebach, DE. (B22D 21/04, OS
10 2005 001 243, AT 11.01.2005)
Verfahren zur Herstellung eines Bauteils
durch Fgen mit Aluminium. Rolls-Roy-
ce Deutschland Ltd & Co KG, 15827 Dah-
lewitz, DE. (B23K 1/19, OS 102 38 551,
AT 22.08.2002)
ALUMINIUM 1-2/2007
Tube aus Metall, insbesondere Alumi-
nium. Karl Hll GmbH & Co KG, 40764
Langenfeld, DE. (B65D 35/16, GM 203 16
148, AT 18.10.2003)
Vorrichtung zur Sicherung von als Paket
gelagerten Aluminium-Stranggusspro-
dukten, so genannten Masseln, zu Trans-
portzwecken. Signode System GmbH,
46535 Dinslaken, DE. (B65D 85/20, GM
20 2006 012 782, AT 21.08.2006)
Verfahren zur Herstellung von Sinter-
krpern aus Yttrium-Aluminium-Granat
und ein Formkrper. NGK Insulators,
Ltd., Nagoya, Aichi, JP. (C04B 35/44, EP
1 433 764, EP-AT 22.12.2003)
Behandeln von Abstandhaltern in gesta-
pelten Aluminium-Blcken. Alcoa Inc.,
Pittsburgh, Pa., US. (C21D 1/70, EP 1 215
289, EP-AT 11.12.2001)
Reinigung von Aluminium-Gusslegie-
rungen mittels Zugabe von Bor. Baye-
rische Motoren Werke AG, 80809 Mn-
chen, DE. (C22B 21/06, EP 1 264 903,
EP-AT 03.05.2003)
Verstellbare Aluminium-Dachhaken mit
Einrastfunktion zur Befestigung von
Solarmodulen und Solarthermieanlagen
auf Dchern und Schrgdchern. Citak,
Fatma, 33689 Bielefeld, DE. (E04D 13/18,
OS 10 2005 058 065, AT 06.12.2005)
Mehrschichtiges Gleitteil aus einer auf
Aluminium basierenden Legierung.
Daido Metal Co. Ltd., Nagoya, Aichi, JP.
(F16C 33/12, PS 10 2004 025 557, AT
25.05.2004)
Isolierverbund fr Aluminium-Profile.
Henkenjohann, Johann, 33415 Verl,
DE. (F16S 3/02, GM 298 21 183, AT
26.11.1998)
Aluminium Strahlungsplatte fr eine
Unterdecke. Riello, Franco, Milano, IT;
Riello, Andrea, Milano, IT; Donati, Giu-
seppe, Cenate Sopra, Bergamo, IT; Do-
nati, Francesco, Cenate Sopra, Bergamo,
IT. (F24D 3/16, EPA 1 703 215, EP-AT
22.02.2005)
Detektorbnder enthaltend Aluminium,
Silizium, Titan und Zirkonium. Oeste,
Franz Dietrich, 35274 Kirchhain, DE.
(G01N 27/26, OS 10 2005 021 625, AT
05.05.2005)
Aluminiumlegierung zur Herstellung
von Gussformteilen. Alcoa Inc., Pitts-
burgh, Pa., US. (C22C 21/00, EPA 1 709
210, EP-AT 31.01.2005)
Verschleifester gestreckter Krper aus
Aluminiumlegierung, Herstellungsver-
fahren dafr und Kolben fr Auto-Kli-
maanlage. Sumitomo Electric Industries,
Ltd., Osaka, JP; Toyoda Automatic Loom
PAT E N T E
Works, Ltd., Kariya, Aichi, JP. (C22C
21/02, OS 102 32 159, AT 16.07.2002)
Verfahren zum Herstellen einer hoch-
schadenstoleranten Aluminiumlegie-
rung. Corus Aluminium Walzprodukte
GmbH, 56070 Koblenz, DE. (C22F 1/04,
WO 2005 049878, WO-AT 29.10.2004)
Einrichtung zur Herstellung gegossener
Halbfabrikate aus Leichtmetall. Stolfig,
Peter, 85290 Geisenfeld, DE. (B22D 21/04,
OS 10 2005 024 025, AT 21.05.2005)
Verfahren zum Leichtmetall-Legierungs-
Sintern. Schwbische Httenwerke
GmbH, 73433 Aalen, DE. (C22C 1/04,
EPA 1 709 209, EP-AT 26.11.2004)
Sinterkrper auf Eisenbasis mit hervor-
ragenden Eigenschaften zum Einbetten
durch Eingieen in Leichtmetall-Legie-
rung und Verfahren zu seiner Herstel-
lung. NIPPON PISTON RING CO., LTD.,
Saitama, JP; Fuji Jukogyo K.K., Tokio/To-
kyo, JP. (C22C 33/02, PS 103 60 824, AT
23.12.2003)
Maschinenteil aus einer Leichtmetall-
Gusslegierung, insbesondere Pleuel
fr Hubkolbenmaschinen. Bayerische
Motoren Werke AG, 80809 Mnchen,
DE. (F16C 7/02, PS 43 32 444, AT
23.09.1993)
Sammelbehlter fr Magnesium o. dgl.
Thielemann, Frank, 63776 Mmbris, DE.
(F16L 3/14, GM 20 2005 008 220, AT
25.05.2005)
Druckgussbauteil, aus Magnesium, vor-
nehmlich zur Verwendung in Kraftfahr-
zeugen. Volkswagen AG, 38440 Wolfs-
burg, DE. (F16S 5/00, OS 100 02 262, AT
19.01.2000)
Verfahren zu Herstellung elektrisch
ALUMINIUM verffentlicht unter
dieser Rubrik regelmig einen ber-
blick ber wichtige, den Werkstoff
Aluminium betreffende Patente. Die
ausfhrlichen Patentbltter und auch
weiterfhrende Informationen dazu
stehen der Redaktion nicht zur Ver-
fgung. Interessenten knnen diese
beziehen oder einsehen bei der
Mitteldeutschen Informations-, Pa-
tent-, Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darber hin-
aus weitere Patent-Dienstleistungen
an.
109
PAT E N T E
leitfhiger und optimal haftfhiger
Oberflchenbereiche auf chemisch und/
oder galvanisch beschichteten und/oder
lackierten Spritzgussteilen aus Magne-
siumlegierungen. Fa. Alfred R. Franz,
82538 Geretsried, DE. (C25D 5/00, PS
198 51 278, AT 06.11.1998)
Schutzschicht fr eine aluminiumhaltige
Legierung fr den Einsatz bei hohen
Temperaturen, sowie Verfahren zur
Herstellung einer solchen Schutzschicht.
Forschungszentrum Jlich GmbH, 52428
Jlich, DE.(C23C 8/02, EPA 1 706 518,
EP-AT 20.11.2004)
Verfahren zum Umformen eines Aus-
gangsprofils od. dgl. Werkstckes so-
wie Profil dafr. Alcan Technology &
Management AG, Neuhausen am Rhein-
fall, CH. (B21D 26/02, PS 199 55 506, AT
18.11.1999)
Verfahren zur Herstellung eines Verpa-
ckungsmaterials. Alcan Technology &
Management Ltd., Neuhausen am Rhein-
fall, CH. (B32B 37/12, EPA 1 621 333, EP-
AT 01.07.2004)
Verbundplatte mit zwei Deckschichten
und einem Kern sowie deren Verwen-
dung und Herstellung. Alcan Technolo-
gy & Management AG, Neuhausen am
Rheinfall, CH. (B32B 5/16, PS 43 17 315,
AT 25.05.1993)
Stossfngersystem. Alcan Technology &
Management AG, Neuhausen am Rhein-
fall, CH. (B60R 19/26, GM 20 2005 016
564, AT 20.10.2005)
Stostange mit Halterungen. Alcan
Technology & Management AG, Neuhau-
sen am Rheinfall, CH. (B60R 19/34, OS 10
2006 019 653, AT 25.04.2006)
Flexibler Trger mit elektrisch leitfhiger
Struktur. Alcan Technology & Manage-
ment Ltd., Neuhausen am Rheinfall,
CH. (H01B 7/08, EPA 1 704 572, EP-AT
17.12.2004)
Verfahren zum Verschlieen eines Be-
hlters sowie Schraubverschluss hierfr.
Alcoa Deutschland GmbH Verpackungs-
werke, 67547 Worms, DE. (B67C 7/00,
OS 199 42 507, AT 07.09.1999)
Halterungselemente fr Bauplatten. Co-
rus Bausysteme GmbH, 56070 Koblenz,
DE. (E04D 3/36, EP 1 147 270, EP-AT
04.01.2000)
Verkleidungsblech. Corus Bausysteme
GmbH, 56070 Koblenz, DE. (E04F 13/12,
GM 200 16 964, AT 27.09.2000)
Bandkanten-Planheitssteuerung. Hydro
Aluminium Deutschland GmbH, 53117
Bonn, DE. (B21B 37/32, PS 102 06 758,
AT 19.02.2002)
110
Gieform zum Gieen von Metallschmel- schine und Verfahren zur Herstellung
ze. Hydro Aluminium Alucast GmbH,
66763 Dillingen, DE. (B22C 1/20, OS 10
2005 023 051, AT 13.05.2005)
Dauergieform und Gieformeinsatz.
Hydro Aluminium Mandl&Berger GmbH,
Linz, AT. (B22C 9/06, PS 10 2005 054
616, AT 16.11.2005)
Verfahren und Vorrichtungen zum F-
gen von mindestens zwei Bauteilen aus
artverschiedenen Werkstoffen. Hydro
Aluminium Deutschland GmbH, 51149
Kln, DE. (B23K 20/12, OS 10 2005 019
758, AT 28.04.2005)
Fassade oder Glasdach in Brandschutz-
ausfhrung mit einer aus vertikalen
und horizontalen Profilen bestehenden
Tragkonstruktion. Norsk Hydro ASA,
Oslo, NO. (E04B 1/94, EP 1 120 504, EP-
AT 20.01.2001)
Verbinder fr Rahmen von Fenstern,
Tren, Fassaden und dergleichen Kon-
struktionen. Norsk Hydro ASA, Oslo,
NO. (E04B 2/96, EP 1 249 550, EP-AT
10.04.2002)
Deckleiste fr Fenster. Norsk Hydro
ASA, Oslo, NO. (E06B 3/30, EPA 1 712
719, EP-AT 04.04.2006)
Einbausystem fr den Einbau eines Pa-
neelrandes in einen Pfosten. Norsk Hy-
dro ASA, Oslo, NO. (E06B 3/54, EPA 1
710 386, EP-AT 04.04.2006)
Tr, Fenster oder hnliches mit einer
drehenden Abdichtung zwischen Flgel
und Rahmen. Norsk Hydro ASA, Oslo,
NO. (E06B 7/22, EPA 1 712 723, EP-AT
04.04.2006)
Lagervorrichtung fr einen Sandbehl-
ter, der in einer Formvorrichtung fr
verlorenen Guss vibriert wird. Fata Alu-
minium S.p.A., Rivoli, IT. (B22C 15/10,
EP 1 153 679, EP-AT 09.05.2000)
Metallschmelzentransportbehlter. Nip-
pon Crucible Co., Ltd., Tokio/Tokyo, JP;
Daiki Aluminium Industry Co., Ltd., Yao-
shi, Osaka, JP. (B22D 35/00, EPA 1 702
700, EP-AT 23.07.2004
Gelndeanpassbarer Zaun. ALTEC Alu-
minium Technik Hans-J. Gebauer GmbH,
56727 Mayen, DE. (E04H 17/14, GM 298
10 603, AT 12.06.1998)
Verfahren zur Herstellung eines Fenster-
bankabschlusses. RBB Aluminium Profil-
technik AG, 54531 Wallscheid, DE. (E06B
1/70, PS 102 50748, AT 31.10.2002)
Fenster- oder Trpfosten. Reynaers Alu-
minium, N.V., Duffel, BE. (E06B 3/263,
EPA 1 705 334, EP-AT 13.02.2006)
Zylinderblock fr eine Brennkraftma-
eines Zylinderblocks. KS Aluminium-
Technologie AG, 74172 Neckarsulm,
DE. (F02F 1/00, PS 10 2004 005 458, AT
04.02.2004)
Profilanordnung und Einfassprofil fr
eine Profilanordnung. MayTec Alumini-
um Systemtechnik GmbH, 85221 Dach-
au, DE. (F16B 5/06, GM 203 21 258, AT
24.04.2003)
Beschichtung fr einen Solarabsor-
ber. ALANOD Aluminium-Veredlung
GmbH & Co. KG, 58256 Ennepetal, DE.
(F24J 2/48, PS 10 2004 060 982, AT
17.12.2004)
Zarge fr ein Fenster oder eine Tr in
wrmegedmmter Ausfhrung. Her-
mann Gutmann Werke GmbH, 91781
Weienburg, DE. (E06B 1/32, PS 100 40
497, AT 18.08.2000)
Halteprofil sowie Fenster- oder Trkon-
struktion. Hermann Gutmann Werke
AG, 91781 Weienburg, DE. (E06B 3/58,
OS 10 2005 023 257, AT 20.05.2005)
Patentblatt Dezember 2006
Verfahren zur Herstellung einer auf
Al-Mg-Si basierenden Aluminiumlegie-
rungsplatte mit hervorragender Bake-
Hardenability. Nippon Light Metal Co.
Ltd., Tokio/Tokyo, JP. (C22C 1/05, EPA
1 715 067, EP-AT 22.12.2004)
Cr-Al-Stahl fr Hochtemperaturanwen-
dungen. Sandvik Intellectual Property
AB, Sandviken, SE. (C22C 38/06, EPA 1
721 023, EP-AT 21.12.2005)
Aluminium-Zirkonium-Antiperspiran-
tien mit verbesserter Wirksamkeit.
Reheis, Inc., Berkeley Heights, N.J., US.
(A61K 8/00, EPA 1 715 831, EP-AT
19.01.2005)
Aluminium-Fahrzeugfelge und Verfah-
ren zum Herstellen einer solchen. bd-
breyton-design GmbH, 78333 Stockach,
DE. (B22D 17/14, OS 10 2005 026 829,
AT 09.06.2005)
Fortsetzung der Dezember-Auswertung in
der nchsten Ausgabe der ALUMINIUM.
Fr
Abonnenten
www.alu-archiv.de
Wissen auf Abruf
ALUMINIUM 1-2/2007
 Lieferverzeichnis

International Journal for Industry, Research and Application

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ALUMINIUM 1-2/2007 111

Lieferverzeichnis

Smelting technology
1 Httentechnik
1.1 Raw materials 1.1 Rohstoffe
1.2 Storage facilities for smelting 1.2 Lagermglichkeiten in der Htte
1.3 Anode production 1.3 Anodenherstellung
1.4 Anode rodding 1.4 Anodenschlgerei
1.5 Casthouse (foundry) 1.5 Gieerei
1.6 Casting machines 1.6 Giemaschinen
1.7 Current supply 1.7 Stromversorgung
1.8 Electrolysis cell (pot) 1.8 Elektrolyseofen
1.9 Potroom 1.9 Elektrolysehalle
1.10 Laboratory 1.10 Labor
1.11 Emptying the cathode shell 1.11 Ofenwannenentleeren
1.12 Cathode repair shop 1.12 Kathodenreparaturwerkstatt
1.13 Second-hand plant 1.13 Gebrauchtanlagen
1.14 Aluminium alloys 1.14 Aluminiumlegierungen

1.2 Storage facilities Auto firing systems 1.4 Anode rodding

Automatische Feuerungssysteme
for smelting Anodenanschlgerei
Lagermglichkeiten
in der Htte
OUTOKUMPU Technology GmbH
Mller Materials Handling GmbH Tel.: +49 (0) 2203 / 9921-0
Haderslebener Strae 7 www.outokumputechnology.com
D-25421 Pinneberg
RIEDHAMMER GmbH
Telefon: 04101 788-0
D-90332 Nrnberg
Telefax: 04101 788-115
E-Mail: info@moeller-mh.com
E-Mail: goede.frank@riedhammer.de Removal of bath residues from
Internet: www.moeller-mh.com
Internet: www.riedhammer.de the surface of spent anodes
Kontakt: Herr Dipl.-Ing. Timo Letz Entfernen der Badreste von der Ober-
flche der verbrauchten Anoden
Exhaust gas treatment
Abgasbehandlung
OUTOKUMPU Technology GmbH
Tel.: +49 (0) 2203 / 9921-0 ALSTOM Norway AS
www.outokumputechnology.com Tel. +47 22 12 70 00
GLAMA Maschinenbau GmbH
Internet: www.environment.power.alstom.com
Hornstrae 19
D-45964 Gladbeck
Hydraulic presses for Telefon 02043 / 9738-0
prebaked anodes Telefax 02043 / 9738-50
Conveying systems
bulk materials Hydraulische Pressen zur
Frderanlagen fr Schttgter Herstellung von Anoden
(Httenaluminiumherstellung) Transport of finished anode
elements to the pot room
Mller Materials Handling GmbH Transport der fertigen Anoden-
Internet: www.moeller-mh.com elemente in Elektrolysehalle
see Storage facilities for smelting 1.2 LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone:+352 27612 0
Fax: +352 27612 109 Vollert GmbH + Co. KG
E-Mail: info@laeis-gmbh.com Anlagenbau
Unloading/Loading equipment Internet: www.laeis-gmbh.com Stadtseestrae 12
Entlade-/Beladeeinrichtungen Contact: Dr. Alfred Kaiser D-74189 Weinsberg
Tel. +49 (0) 7134 / 52-228
Fax +49 (0) 7134 / 52-203
Mller Materials Handling GmbH Open top and closed E-Mail vertrieb@vollert.de
Internet: www.moeller-mh.com type baking furnaces Internet www.vollert.de
see Storage facilities for smelting 1.2 Offene und geschlossene Ringfen

1.3 Anode production

Anodenherstellung
Hovestr. 10 . D-48431 Rheine
RIEDHAMMER GmbH Telefon + 49 (0) 59 71 58-0
OUTOKUMPU Technology GmbH D-90332 Nrnberg Fax + 49 (0) 59 71 58-209
Tel.: +49 (0) 2203 / 9921-0 E-Mail: goede.frank@riedhammer.de E-Mail info@windhoff.de
www.outokumputechnology.com Internet: www.riedhammer.de Internet www.windhoff.de

112 ALUMINIUM 1-2/2007

 Lieferverzeichnis

1.5 Casthouse (foundry) Measurement & Testing Bone ash

Temperaturmessung Knochenasche
Gieerei

INOTHERM INDUSTRIEOFEN- IMPERIAL-OEL-IMPORT

UND WRMETECHNIK GMBH Bergstrae 11, D 20095 Hamburg
Konstantinstrae 1a Tel. 040/338533-0, Fax: 040/338533-85
D 41238 Mnchengladbach Gieereiprodukte Foundry Products E-Mail: info@imperial-oel-import.de
Telefon +49 (02166) 987990 Balthasar Floriszstraat 34-36/oh
Telefax +49 (02166) 987996 NL-1071 VD AMSTERDAM
E-Mail: info@inotherm-gmbh.de Tel.: +31 20 693-5209, Fax -5762 Furnace charging with
Internet: www.inotherm-gmbh.de Internet: www.srsamsterdam.com molten metal
Ofenbeschickung mit Flssigmetall
Metal treatment in the
holding furnace GLAMA Maschinenbau GmbH
Metallbehandlung in Haltefen see Anode rodding 1.4
THERMCON OVENS BV
see Extrusion 2 maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1 1.6 Casting machines
SIGNODE SYSTEM GMBH Giemaschinen
Packaging Equipment
Non-Ferrous Specialist Team DSWE Transfer to the
Magnusstr. 18, 46535 Dinslaken/Germany casting furnace
Telefon: +49 (0) 2064 / 69-210 berfhrung in Gieofen
Telefax: +49 (0) 2064 / 69-489
E-Mail: g.laks@signode-europe.com
Internet: www.signode.com GLAMA Maschinenbau GmbH THERMCON OVENS BV
see Anode rodding 1.4 see Extrusion 2
Contact: Mr. Gerard Laks
Drache Umwelttechnik
Stopinc AG GmbH
Bsch 83 a Werner-v.-Siemens-Strae 9/24-26 Pig casting machines
CH-6331 Hnenberg D 65582 Diez/Lahn (sow casters)
Tel. +41/41-785 75 00 Telefon 06432/607-0 Masselgiemaschine (Sowcaster)
Fax +41/41-785 75 01 Telefax 06432/607-52
E-Mail: interstop@stopinc.ch Internet: www.drache-gmbh.de
Internet: www.stopinc.ch
maerz-gautschi
maerz-gautschi Industrieofenanlagen GmbH
Transport of liquid metal Industrieofenanlagen GmbH see Casting Equipment 3.1
to the casthouse see Casting Equipment 3.1
Transport von Flssigmetall
in Gieereien Vollert GmbH + Co. KG
Anlagenbau
GLAMA Maschinenbau GmbH
see Transport of finished anode elements
see Anode rodding 1.4
to the pot room 1.4
MARX GmbH & Co. KG
Windhoff Bahn- und HERTWICH ENGINEERING GmbH
www.marx-gmbh.de
Anlagentechnik GmbH Maschinen und Industrieanlagen
see Melt operations 4.13
see Anode rodding 1.4 Weinbergerstrae 6, A-5280 Braunau am Inn
Vollert GmbH + Co. KG Phone +437722/806-0
Anlagenbau Fax +437722/806-122
Treatment of casthouse E-Mail: info@hertwich.com
see Transport of finished anode elements off gases
to the pot room 1.4 Internet: www.hertwich.com
Behandlung der Gieereiabgase

Windhoff Bahn- und maerz-gautschi

Anlagentechnik GmbH Industrieofenanlagen GmbH
see Anode rodding 1.4 see Casting Equipment 3.1

see Equipment and accessories 2.11

Dross skimming of
liquid metal
Abkrtzen des Flssigmetalls
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Melting/holding/casting
furnaces
Schmelz-/Halte- und Giessfen
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
Degassing, filtration and
grain refinement
Entgasung, Filtern, Kornfeinung Rolling and extrusion ingot
Drache Umwelttechnik and T-bars
GmbH Formatgieerei (Walzbarren oder
Werner-v.-Siemens-Strae 9/24-26 Pressbolzen oder T-Barren)
D 65582 Diez/Lahn
Telefon 06432/607-0 Cast-Tec GmbH & Co. KG
Telefax 06432/607-52 Fertigungstechnik & Service
Internet: www.drache-gmbh.de D-44536 Lnen, Brunnenstrae 138
Telefon: 02306/20310-0
maerz-gautschi Telefax: 02306/20310-11
Industrieofenanlagen GmbH E-Mail: Info@cast-tec.de
see Casting Equipment 3.1 Internet: www.cast-tec.de

ALUMINIUM 1-2/2007 113

Lieferverzeichnis
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
Vertical semi-continuous
DC casting
Vertikales Stranggieen
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
see Equipment and accessories 2.11
Horizontal continuous casting
Horizontales Stranggieen
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
Scales
Waagen
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
114
Sawing Pot feeding systems
Sgen Beschickungseinrichtungen
fr Elektrolysezellen
Mller Materials Handling GmbH
Internet: www.moeller-mh.com
see Storage facilities for smelting 1.2
Slurries and parting agents
HERTWICH ENGINEERING GmbH
Schlichten und Trennmittel
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn ESK Ceramics GmbH & Co. KG
Phone +437722/806-0 Max-Schaidhauf-Strae 25
Fax +437722/806-122 87437 Kempten, Germany
E-Mail: info@hertwich.com Tel.: +49 831 5618-0, Fax: -345
Internet: www.hertwich.com Internet: www.esk.com
maerz-gautschi
Industrieofenanlagen GmbH 1.9 Potroom
see Casting Equipment 3.1
Elektrolysehalle
Heat treatment of extrusion
ingot (homogenisation) T.T. Tomorrow Technology S.p.A.
Via dellArtigianato 18
Formatebehandlung
(homogenisieren) Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
E-Mail: gmagarotto@tomorrowtechnology.it
Contact: Giovanni Magarotto
Anode changing machine
Anodenwechselmaschine
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen GLAMA Maschinenbau GmbH
Weinbergerstrae 6, A-5280 Braunau am Inn see Anode rodding 1.4
Phone +437722/806-0
Fax +437722/806-122 Tapping vehicles
E-Mail: info@hertwich.com Schpffahrzeuge
Internet: www.hertwich.com
GLAMA Maschinenbau GmbH
maerz-gautschi see Anode rodding 1.4
Industrieofenanlagen GmbH
see Casting Equipment 3.1
Crustbreakers
Krustenbrecher
Casthouse machines
Gieereimaschinen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Cast-Tec GmbH & Co. KG
Fertigungstechnik & Service
see Casting machines 1.6 Dry absorption units for
electrolysis exhaust gases
1.7 Current supply Trockenabsorptionsanlage fr
Elektrolyseofenabgase
Stromversorgung
ALSTOM Norway AS
Busbars
Stromschienen Tel. +47 22 12 70 00
Internet: www.environment.power.alstom.com
Cast-Tec GmbH & Co. KG
Fertigungstechnik & Service Anode transport equipment
see Casting machines 1.6 Anoden Transporteinrichtungen
1.8 Electrolysis cell GLAMA Maschinenbau GmbH
see Anode rodding 1.4
(pot)
Elektrolyseofen
HF Measurementtechnology
Insulating bricks HF Messtechnik
Isoliersteine
OPSIS AB
Promat GmbH Techn. Wrmedmmung Box 244, S-24402 Furulund, Schweden
Scheifenkamp 16, D-40878 Ratingen Tel. +46 (0) 46-72 25 00, Fax -72 25 01
Tel. +49 (0) 2102 / 493-0, Fax -493 115 E-Mail: info@opsis.se
verkauf3@promat.de, www.promat.de Internet: www.opsis.se
ALUMINIUM 1-2/2007

Extrusion
2
2.1
Strangpressen
Extrusion billet preparation
2.2 Extrusion equipment
2.3 Section handling
2.4 Heat treatment
2.5 Measurement and control equipment
2.6 Die preparation and care
2.7 Second-hand extrusion plant
2.8 Consultancy, expert opinion
2.9 Surface finishing of sections
2.10 Machining of sections
2.11 Equipment and accessories
2.12 Services
www.otto-junker-group.com
Jgerhausstr. 22
D 52152 Simmerath
Telefon: +49 2473 601 0
Telefax: +49 2473 601 600
E-Mail: info@otto-junker.de
Kontakt: Herr Teichert
Rudolf-Diesel-Str. 1-3
D 78239 Rielasingen-Worblingen
Telefon +49 7731 5998-0
Telefax +49 7731 5998-90
E-Mail info@elhaus.de
Kontakt: Herr Dr. Menzler
De Chamotte 4
NL 4191 GT GELDERMALSEN
Telefon: +31 345 574141
Telefax: +31 345 576322
E-Mail: info@thermcon.com
Kontakt: Herr Schmidt
Kingsbury Road
Curdworth
UK - SUTTON COLDFIELD B76 9EE
Telefon: +44 1675 470551
Telefax: +44 1675 470645
E-Mail: info@otto-junker.co.uk
Kontakt: Mr. Beard
ALUMINIUM 1-2/2007
Lieferverzeichnis
2.1 Pressbolzenbereitstellung
2.2 Strangpresseinrichtungen
2.3 Profilhandling
2.4 Wrmebehandlung
2.5 Mess- und Regeleinrichtungen
2.6 Werkzeugbereitstellung und -pflege
2.7 Gebrauchte Strangpressanlagen
2.8 Beratung, Gutachten
2.9 Oberflchenveredlung von Profilen
2.10 Profilbearbeitung
2.11 Ausrstungen und Hilfsmittel
2.12 Dienstleistungen
2.1 Extrusion billet Billet heating units
Anlagen zur Bolzenerwrmung
preparation
Pressbolzenbereitstellung
SIGNODE SYSTEM GMBH
Packaging Equipment OTTO JUNKER GmbH
Non-Ferrous Specialist Team DSWE ELHAUS INDUSTRIEANLAGEN GmbH
Magnusstr. 18, 46535 Dinslaken/Germany OTTO JUNKER (UK) LTD.
Telefon: +49 (0) 2064 / 69-210 see Extrusion 2
Telefax: +49 (0) 2064 / 69-489
E-Mail: g.laks@signode-europe.com
Internet: www.signode.com
Contact: Mr. Gerard Laks
Billet transport and
storage equipment
Billet heating furnaces Bolzen-Transport- und
Lagereinrichtungen
fen zur Bolzenerwrmung
OTTO JUNKER GmbH
ELHAUS INDUSTRIEANLAGEN GmbH
Am groen Teich 16+27 see Extrusion 2
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de Hot shears
Warmscheren
OTTO JUNKER GmbH
ELHAUS INDUSTRIEANLAGEN GmbH
MARX GmbH & Co. KG THERMCON OVENS BV
www.marx-gmbh.de see Extrusion 2
see Melt operations 4.13
2.2 Extrusion equipment
Strangpresseinrichtungen
Oilgear Towler GmbH
Im Gotthelf 8
Sistem Teknik Ltd. Sti. D 65795 Hattersheim
DES San. Sit. 102 SOK No: 6/8 Tel. +49 (0) 6145 3770
Y.Dudullu, TR-34775 Istanbul/Turkey Fax +49 (0) 6145 30770
Tel.: +90 216 420 86 24 E-Mail: info@oilgear.de
Fax: +90 216 420 23 22 Internet: www.oilgear.de
115
Lieferverzeichnis

Press control systems Packaging equipment

Pressensteuersysteme Verpackungseinrichtungen
H+H HERRMANN + HIEBER GMBH
Frdersysteme fr Paletten
Oilgear Towler GmbH und schwere Lasten
see Extrusion Equipment 2.2 Rechbergstrae 46
D-73770 Denkendorf/Stuttgart
SMS Eumuco GmbH
Tel. +49 (0) 711 / 9 34 67-0
Josefstrae 10
Fax +49 (0) 711 / 3 46 0911
D-51377 Leverkusen
E-Mail: info@herrmannhieber.de
Tel. 0214 / 734-01
Internet: www.herrmannhieber.de
Fax 0214 / 734-1000
E-Mail: info@sms-eumuco.de
Internet: www.sms-eumuco.com Vollert GmbH + Co. KG
Anlagenbau
SMS Eumuco GmbH
see Extrusion equipment 2.2
see Transport of finished anode elements
Containers to the pot room 1.4
Rezipienten
Temperature measurement
Temperaturmessung

KIND & CO., EDELSTAHLWERK, KG

Bielsteiner Strae 128-130
D-51674 Wiehl
Telefon: +49 (0) 2262 / 84 0
Telefax: +49 (0) 2262 / 84 175
E-Mail: info@kind-co.de
Internet: www.kind-co.de
Hinterbergstrasse 26
CH-6330 Cham, Switzerland
Tel.: +41 41 741 5741
Fax: +41 41 741 5760
SMS Eumuco GmbH E-mail: bold.ch@fromm-pack.com
see Extrusion equipment 2.2 Internet: www.fromm-pack.com
Sales Contact: Benno Arnet

Heating and control

equipment for intelligent Puller equipment
billet containers Ausziehvorrichtungen/Puller
Heizungs- und Kontrollausrstung
fr intelligente Blockaufnehmer

OTTO JUNKER GmbH

ELHAUS INDUSTRIEANLAGEN GmbH
THERMCON OVENS BV
S+C MRKER GmbH see Extrusion 2
Steel Technologies
D-51779 Lindlar-Kaiserau
Postfach 11 40 MARX GmbH & Co. KG
Tel.: +49 (0) 2266 / 92 211 www.marx-gmbh.de
Fax: +49 (0) 2266 / 92 509 see Melt operations 4.13
E-Mail: extrusion@schmidt-clemens.de
Internet: www.sc-maerker.de
2.3 Section handling
Profilhandling SMS Eumuco GmbH
see Extrusion equipment 2.2

SIGNODE SYSTEM GMBH

Packaging Equipment Section cooling
Non-Ferrous Specialist Team DSWE Profilkhlung
Magnusstr. 18, 46535 Dinslaken/Germany
SMS Eumuco GmbH Telefon: +49 (0) 2064 / 69-210
see Extrusion equipment 2.2 Telefax: +49 (0) 2064 / 69-489
E-Mail: g.laks@signode-europe.com
Internet: www.signode.com OTTO JUNKER GmbH
Contact: Mr. Gerard Laks ELHAUS INDUSTRIEANLAGEN GmbH
see Extrusion 2
Extrusion
Strangpressen
Homogenising furnaces
Homogenisierfen

OTTO JUNKER GmbH

ELHAUS INDUSTRIEANLAGEN GmbH
OTTO JUNKER (UK) LTD. OTTO JUNKER GmbH SMS Eumuco GmbH
see Extrusion 2 see Extrusion 2 see Extrusion equipment 2.2

116 ALUMINIUM 1-2/2007

 Lieferverzeichnis

Section saws Stackers / Destackers Vollert GmbH + Co. KG

Profilsgen Stapler / Entstapler Anlagenbau

see Transport of finished anode elements

to the pot room 1.4

OTTO JUNKER GmbH OTTO JUNKER GmbH

ELHAUS INDUSTRIEANLAGEN GmbH ELHAUS INDUSTRIEANLAGEN GmbH
see Extrusion 2 see Extrusion 2
2.4 Heat treatment
Wrmebehandlung

Extrusion
Strangpressen

SMS Eumuco GmbH SMS Eumuco GmbH

see Extrusion equipment 2.2 see Extrusion equipment 2.2
OTTO JUNKER GmbH
ELHAUS INDUSTRIEANLAGEN GmbH
OTTO JUNKER (UK) LTD.
Stretching equipment see Extrusion 2
Section store equipment Reckeinrichtungen
Profil-Lagereinrichtungen

H+H HERRMANN + HIEBER GMBH

Heat treatment furnaces
Frdersysteme fr Paletten OTTO JUNKER GmbH Wrmebehandlungsfen
und schwere Lasten ELHAUS INDUSTRIEANLAGEN GmbH
Rechbergstrae 46 see Extrusion 2 INOTHERM INDUSTRIEOFEN-
D-73770 Denkendorf/Stuttgart UND WRMETECHNIK GMBH
Tel. +49 (0) 711 / 9 34 67-0 see Casthouse (foundry) 1.5
Fax +49 (0) 711 / 3 46 0911
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de Sistem Teknik Ltd. Sti.
see Billet Heating Furnaces 2.1

SMS Eumuco GmbH

KASTO Maschinenbau GmbH & Co. KG see Extrusion equipment 2.2
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
kasto@kasto.de / www.kasto.de
Hersteller von Band- und Kreissgemaschinen
sowie Langgut- und Blechlagersystemen Transport equipment for
extruded sections
Transporteinrichtungen
Vollert GmbH + Co. KG fr Profilabschnitte
Anlagenbau
H+H HERRMANN + HIEBER GMBH
see Transport of finished anode elements Frdersysteme fr Paletten
to the pot room 1.4 und schwere Lasten
Rechbergstrae 46
D-73770 Denkendorf/Stuttgart
Tel. +49 (0) 711 / 9 34 67-0
Fax +49 (0) 711 / 3 46 0911
Section transport equipment E-Mail: info@herrmannhieber.de
Profiltransporteinrichtungen Internet: www.herrmannhieber.de
IUT Industriell Ugnsteknik AB
Industrivgen 2, 43892 Hrryda, Sweden
Tel. +46 (0) 301 31510
Fax +46 (0) 301 30479
E-Mail: office@iut.se
Internet: www.iut.se
Custom designed heat
processing equipment
Kundenspezifische
Wrmebehandlungsanlagen
Sistem Teknik Ltd. Sti.
see Billet Heating Furnaces 2.1

OTTO JUNKER GmbH

ELHAUS INDUSTRIEANLAGEN GmbH ELHAUS INDUSTRIEANLAGEN GmbH Do you need
see Extrusion 2 see Extrusion 2
more
information?
E-Mail:
SMS Eumuco GmbH SMS Eumuco GmbH Schwichtenberg@giesel.de
see Extrusion equipment 2.2 see Extrusion equipment 2.2

ALUMINIUM 1-2/2007 117

Lieferverzeichnis

Homogenising furnaces 2.6 Die preparation and care 2.10 Machining of sections
Homogenisierfen
Werkzeugbereitstellung Profilbearbeitung
und -pflege
Processing of Profiles
Castool Tooling Solutions Profilbearbeitung
(North America)
21 State Crown Bvld
Scarborough Ontario Canada MIV 4B1
Tel.: +1 416 297 1521
HERTWICH ENGINEERING GmbH Fax: +1 416 297 1915
Maschinen und Industrieanlagen E-Mail: sales@castool.com Tensai (International) AG
Weinbergerstrae 6, A-5280 Braunau am Inn Internet: www.castool.com Extal Division
Phone +437722/806-0 Sales Contact: Danny Dann Steinengraben 40
Fax +437722/806-122 CH-4051 Basel
E-Mail: info@hertwich.com Telefon +41 (0) 61 284 98 10
Internet: www.hertwich.com
Telefax +41 (0) 61 284 98 20
E-Mail: tensai@tensai.com

IUT Industriell Ugnsteknik AB SMS Eumuco GmbH 2.11 Equipment and

see Heat treatment 2.4 see Extrusion equipment 2.2 accessories
Ausrstungen und
Die heating furnaces Hilfsmittel
Werkzeuganwrmfen
Inductiv heating equipment
IUT Industriell Ugnsteknik AB Induktiv beheizte
see Heat treatment 2.4 Erwrmungseinrichtungen

MARX GmbH & Co. KG

www.marx-gmbh.de
Sistem Teknik Ltd. Sti. see Melt operations 4.13
see Billet Heating Furnaces 2.1

Sistem Teknik Ltd. Sti. Am groen Teich 16+27

2.5 Measurement and see Billet Heating Furnaces 2.1
D-58640 Iserlohn
control equipment Tel. +49 (0) 2371 / 4346-0
Mess- und Regeleinrichtungen Extrusion dies Fax +49 (0) 2371 / 4346-43
Strangpresswerkzeuge E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de
Extrusion plant control systems
Presswerkssteuerungen

Ageing furnace for extrusions

Haarmann Holding GmbH Auslagerungsfen fr
Ludwigsallee 57 Strangpressprofile
D-52052 Aachen
Telefon: 02 41 / 9 18 - 500
Telefax: 02 41 / 9 18 - 5010
SMS Eumuco GmbH
E-Mail: info.holding@haarmann-gruppe.de
see Extrusion equipment 2.2 Internet: www.haarmann-gruppe.de
LOI Thermprocess GmbH
Am Lichtbogen 29
Hardness measuring Hardening technology D-45141 Essen
instuments, portable Hrtetechnik Germany
Telefon +49 (0) 201 / 18 91-3 10
Hrtemessgert, tragbar
Telefax +49 (0) 201 / 18 91-53 10
Form+Test Seidner & Co. GmbH
Haarmann Holding GmbH E-Mail: info@loi.de
Internet: www.loi.de
see Die preparation and care 2.6
D-88491 Riedlingen
Telefax 07371/9302-98
E-Mail: linke@formtest.de Sistem Teknik Ltd. Sti.
see Billet Heating Furnaces 2.1
Temperatur measurement 2.7 Second-hand
Temperaturmessung extrusion plant
Gebr. Strangpressanlagen
2.12 Services
Dienstleistungen
Qualiteam International/ExtruPreX
ELHAUS INDUSTRIEANLAGEN GmbH Champs Elysesweg 17, NL-6213 AA Maastricht
THERMCON OVENS BV Tel. +31-43-3 25 67 77 Haarmann Holding GmbH
see Extrusion 2 Internet: www.extruprex.com see Die preparation and care 2.6

118 ALUMINIUM 1-2/2007

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Rolling mill technology

3
3.1
Walzwerktechnik
Casting equipment 3.1 Gieanlagen
3.2 Rolling bar machining 3.2 Walzbarrenbearbeitung
3.3 Rolling bar furnaces 3.3 Walzbarrenvorbereitung
3.4 Hot rolling equipment 3.4 Warmwalzanlagen
3.5 Strip casting units and accessories 3.5 Bandgieanlagen und Zubehr
3.6 Cold rolling equipment 3.6 Kaltwalzanlagen
3.7 Thin strip / foil rolling plant 3.7 Feinband-/Folienwalzwerke
3.8 Auxiliary equipment 3.8 Nebeneinrichtungen
3.9 Adjustment devices 3.9 Adjustageeinrichtungen
3.10 Process technology / Automation technology 3.10 Prozesstechnik / Automatisierungstechnik
3.11 Coolant / lubricant preparation 3.11 Khl-/Schmiermittel-Aufbereitung
3.12 Air extraction systems 3.12 Abluftsysteme
3.13 Fire extinguishing units 3.13 Feuerlschanlagen
3.14 Storage and dispatch 3.14 Lagerung und Versand
3.15 Second-hand rolling equipment 3.15 Gebrauchtanlagen
3.16 Coil storage systems 3.16 Coil storage systems
3.17 Strip Processing Lines 3.17 Bandprozesslinien

3.1 Casting equipment Filling level indicators

Gieanlagen and controls
Fllstandsanzeiger und -regler

OTTO JUNKER GmbH
THERMCON OVENS BV
see Extrusion 2
Melting and holding furnaces
Schmelz- und Warmhaltefen
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
Melt purification units
Schmelzereinigungsanlagen
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
Internet: www.sms-demag.com
E-Mail: communications@sms-demag.com
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch
Telefon: (02733) 29-0
Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
D-40724 Hilden
Telefon: (0211) 8 81-5100
Telefax: (0211) 8 81-5200
Bar scalping
Barrenfrsen

3.2 Rolling bar machining

see Equipment and accessories 2.11 Walzbarrenbearbeitung
maerz-gautschi Band saws / Bandsgen
Industrieofenanlagen GmbH SMS Demag Aktiengesellschaft
Geschftsbereich Aluminium see Rolling bar machining 3.2
Konstanzer Strae 37
Postfach 170 Slab milling machines
CH 8274 Tgerwilen Barrenfrsmaschinen
Telefon +41/71/6666666
Telefax +41/71/6666688
E-Mail: aluminium@maerz-gautschi.ch
Kontakt: Stefan Blum, Tel. +41/71/6666621
SMS Meer GmbH
Metal filters Ohlerkirchweg 66
Metallfilter D-41069 Mnchengladbach
Tel. +49 (0) 2161 / 35 00
maerz-gautschi Fax +49 (0) 2161 / 35 06 67
Industrieofenanlagen GmbH E-Mail: info@sms-meer.com SMS Meer GmbH
see Casting equipment 3.1 Internet: www.sms-meer.com see Rolling bar machining 3.2

ALUMINIUM 1-2/2007 119

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3.3 Rolling bar furnaces
Walzbarrenvorbereitung
Homogenising furnaces
Homogenisierfen
IUT Industriell Ugnsteknik AB
see Heat treatment 2.4
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
OTTO JUNKER GmbH
see Extrusion 2
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
Bar heating furnaces Hot rolling units /
Barrenanwrmanlagen complete plants
Warmwalzanlagen/Komplettanlagen
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
OTTO JUNKER GmbH Internet: http://www.sms-demag.com
THERMCON OVENS BV E-Mail: communications@sms-demag.com
see Extrusion 2
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
Roller tracks D-57271 Hilchenbach-Dahlbruch
Rollengnge Telefon: (02733) 29-0
Telefax: (02733) 29-28 52
Bandanlagen
maerz-gautschi
Walderstrae 51/53
Industrieofenanlagen GmbH D-40724 Hilden
see Casting equipment 3.1 Telefon: (0211) 8 81-5100
Telefax: (0211) 8 81-5200
3.4 Hot rolling equipment
Warmwalzanlagen Rolling mill modernisation
Walzwerksmodernisierung

Achenbach Buschhtten GmbH

Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Demag Aktiengesellschaft
see Hot rolling equipment 3.4

SIEMAG GmbH Spools / Haspel

Obere Industriestrae 8
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Annealing furnaces Fax: +49 (0) 2738 / 21-503
E-Mail: metals@siemag.com
Glhfen
Internet: www.siemag.com

Coil transport systems SMS Demag Aktiengesellschaft

EBNER Industrieofenbau Ges.m.b.H. see Hot rolling equipment 3.4
Ruflinger Str. 111, A-4060 Leonding Bundtransportsysteme
Tel. +43 / 732 / 68 68
Fax +43 / 732 / 68 68-1000
Vollert GmbH + Co. KG Toolings / Werkzeuge
Anlagenbau
Internet: www.ebner.cc
E-Mail: sales@ebner.cc see Transport of finished anode elements
to the pot room 1.4
IUT Industriell Ugnsteknik AB see Extrusion equipment 2.2
see Heat treatment 2.4 Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
Do you need
Drive systems / Antriebe
OTTO JUNKER GmbH
see Extrusion 2
more
maerz-gautschi
information?
Industrieofenanlagen GmbH
see Casting equipment 3.1
E-Mail:
schwartz GmbH SMS Demag Aktiengesellschaft Schwichtenberg@giesel.de
see Heat treatment 2.4 see Hot rolling equipment 3.4

120 ALUMINIUM 1-2/2007

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3.5 Strip casting units SIGNODE SYSTEM GMBH

and accessories
Bandgieanlagen und
Zubehr
Cores & shells for continuous
casting lines
Cores & shells for continuous
casting lines
Bruno Presezzi, Officine Meccaniche
Via per Ornago 8
I-20040 Burago Molgora (Mi) Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.presezzicaster.com
Contact: Franco Gramaglia
Revamps, equipments & spare parts
for continuous casting lines
Revamps, equipments & spare parts
for continuous casting lines
Bruno Presezzi, Officine Meccaniche
Via per Ornago 8
I-20040 Burago Molgora (Mi) Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.presezzicaster.com
Contact: Franco Gramaglia
Twin-roll continuous casting
lines (complete lines)
Twin-roll continuous casting lines
(complete lines)
Packaging Equipment
Non-Ferrous Specialist Team DSWE
Magnusstr. 18, 46535 Dinslaken/Germany
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
E-Mail: g.laks@signode-europe.com
Internet: www.signode.com SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
Contact: Mr. Gerard Laks
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
Coil transport systems Internet: http://www.sms-demag.com
Bundtransportsysteme E-Mail: communications@sms-demag.com
Geschftsbereiche:
Vollert GmbH + Co. KG Warmflach- und Kaltwalzwerke
Anlagenbau Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch
see Transport of finished anode elements Telefon: (02733) 29-0
to the pot room 1.4 Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
Windhoff Bahn- und D-40724 Hilden
Anlagentechnik GmbH Telefon: (0211) 8 81-5100
see Anode rodding 1.4 Telefax: (0211) 8 81-5200
Drive systems
Coil annealing furnaces Antriebe
Bundglhfen
IUT Industriell Ugnsteknik AB
see Heat treatment 2.4
SMS Demag Aktiengesellschaft
see Hot rolling equipment 3.4
OTTO JUNKER GmbH
see Extrusion 2
Heating furnaces
Anwrmfen

Bruno Presezzi, Officine Meccaniche

Via per Ornago 8
I-20040 Burago Molgora (Mi) Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.presezzicaster.com
Contact: Franco Gramaglia
3.6 Cold rolling equipment
Kaltwalzanlagen
see Equipment and accessories 2.11 OTTO JUNKER GmbH
see Extrusion 2
maerz-gautschi
Industrieofenanlagen GmbH maerz-gautschi
see Casting equipment 3.1 Industrieofenanlagen GmbH
see Casting equipment 3.1
schwartz GmbH
see Cold colling equipment 3.6

www.vits.com
see Cold rolling equipment 3.6

Achenbach Buschhtten GmbH

Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SIEMAG GmbH
Obere Industriestrae 8
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-503
E-Mail: metals@siemag.com
Internet: www.siemag.com
Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
Vits Systems GmbH
Winkelsweg 172
D-40764 Langenfeld
Tel.: +49 (0) 2173 / 798-0
Fax: +49 (0) 2173 / 798-244
E-Mail: mt@vits.de, Internet: www.vits.com
Process optimisation systems
Prozessoptimierungssysteme
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1

ALUMINIUM 1-2/2007 121

Lieferverzeichnis
Process simulation
Prozesssimulation
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
SMS Demag Aktiengesellschaft
see Cold colling equipment 3.6
Revamps, equipments & spare parts
Revamps, equipments & spare parts
Bruno Presezzi, Officine Meccaniche
Via per Ornago 8
I-20040 Burago Molgora (Mi) Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.presezzicaster.com
Contact: Franco Gramaglia
Roll exchange equipment
Walzenwechseleinrichtungen
SMS Demag Aktiengesellschaft
see Hot rolling equipment 3.4
Vollert GmbH + Co. KG
Anlagenbau
see Transport of finished anode elements
to the pot room 1.4
Windhoff Bahn- und
Anlagentechnik GmbH
see Anode rodding 1.4
Rolling mill modernization
Walzwerkmodernisierung
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Strip rolling mills
Bandwalzwerke
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
122
Strip shears
Bandscheren
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
SMS Demag Aktiengesellschaft
see Hot rolling equipment 3.4
Trimming equipment
Besumeinrichtungen
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
SMS Demag Aktiengesellschaft
see Hot rolling equipment 3.4
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SIGNODE SYSTEM GMBH
Packaging Equipment
Non-Ferrous Specialist Team DSWE
Magnusstr. 18, 46535 Dinslaken/Germany
Telefon: +49 (0) 2064 / 69-210
Telefax: +49 (0) 2064 / 69-489
E-Mail: g.laks@signode-europe.com
Internet: www.signode.com
Contact: Mr. Gerard Laks
Coil annealing furnaces
Bundglhfen
OTTO JUNKER GmbH
see Extrusion 2
see Equipment and accessories 2.11
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
schwartz GmbH
see Cold colling equipment 3.6
www.vits.com
see Thin strip / foil rolling plant 3.7
Heating furnaces
Anwrmfen
INOTHERM INDUSTRIEOFEN-
UND WRMETECHNIK GMBH
see Casthouse (foundry) 1.5
OTTO JUNKER GmbH
see Extrusion 2
maerz-gautschi
Industrieofenanlagen GmbH
see Casting equipment 3.1
Vits Systems GmbH
Winkelsweg 172
D-40764 Langenfeld
Tel.: +49 (0) 2173 / 798-0
Fax: +49 (0) 2173 / 798-244
E-Mail: mt@vits.de, Internet: www.vits.com
Revamps, equipments & spare parts
Revamps, equipments & spare parts
Bruno Presezzi, Officine Meccaniche
Via per Ornago 8
I-20040 Burago Molgora (Mi) Italy
Tel. +39 039 63502 229
Fax +39 039 6081373
E-Mail: aluminium.dept@brunopresezzi.com
Internet: www.presezzicaster.com
Contact: Franco Gramaglia
ALUMINIUM 1-2/2007

Rolling mill modernization
Walzwerkmodernisierung
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
Internet: http://www.sms-demag.com
E-Mail: communications@sms-demag.com
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch
Telefon: (02733) 29-0
Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
D-40724 Hilden
Telefon: (0211) 8 81-5100
Telefax: (0211) 8 81-5200
3.9 Adjustment devices /
Adjustageeinrichtungen
Transverse cutting units
Querteilanlagen
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
Longitudinal splitting units
Lngsteilanlagen
Danieli Frhling
Finkenstrasse 19
D-57462 Olpe
Germany
Tel.: +49 (0) 27 61 / 894-0
Fax: +49 (0) 27 61 / 894-200
E-Mail: d.neumann@danieli-froehling.de
Internet: www.danieli-froehling.de
Sales Contact: Detlef Neumann
ALUMINIUM 1-2/2007
Sheet and plate stretchers
Blech- und Plattenstrecker
SMS Meer GmbH
see Rolling bar machining 3.2
Cable sheathing presses
Kabelummantelungspressen
SMS Meer GmbH
see Rolling bar machining 3.2
Cable undulating machines
Kabelwellmaschinen
SMS Meer GmbH
see Rolling bar machining 3.2
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
4Production AG
Produktionsoptimierende Lsungen
Adenauerstrae 20, D-52146 Wrselen
Tel.: +49 (0) 2405 / 4135-0
info@4production.de, www.4production.de
SIEMAG GmbH
Obere Industriestrae 8
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-503
E-Mail: metals@siemag.com
Internet: www.siemag.com
Process control technology
Prozessleittechnik
SMS Demag Aktiengesellschaft
see Process technology/
Automation technology 3.10
Unitechnik Cieplik & Poppek AG
D-51674 Wiehl, www.unitechnik.com
Lieferverzeichnis
Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
ABB Automation Technologies AB
Force Measurement
S-72159 Vsteras, Sweden
Phone: +46 21 342000
Fax: +46 21 340005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
SMS Demag Aktiengesellschaft
see Process technology/
Automation technology 3.10
Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
Internet: http://www.sms-demag.com
E-Mail: communications@sms-demag.com
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch
Telefon: (02733) 29-0
Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
D-40724 Hilden
Telefon: (0211) 8 81-5100
Telefax: (0211) 8 81-5200
123
Lieferverzeichnis
ABB Automation Technologies AB
Force Measurement
S-72159 Vsteras, Sweden
Phone: +46 21 342000
Fax: +46 21 340005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
3.11 Coolant / lubricant
preparation
Khl-/Schmiermittel-
Aufbereitung
Rolling oil recovery and
treatment units
Walzl-Wiederaufbereitungsanlagen
SMS Demag Aktiengesellschaft
Eduard-Schloemann-Strae 4
D-40237 Dsseldorf
Telefon: (0211) 8 81-0
Telefax: (0211) 8 81-49 02
Internet: http://www.sms-demag.com
E-Mail: communications@sms-demag.com
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch
Telefon: (02733) 29-0
Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
D-40724 Hilden
Telefon: (0211) 8 81-5100
Telefax: (0211) 8 81-5200
Filter for rolling oils and
emulsions
Filter fr Walzle und Emulsionen
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Rolling oil rectification units
Walzlrektifikationsanlagen
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
124
3.16 Coil storage systems
Bundlagersysteme
SIEMAG GmbH
SMS Demag Aktiengesellschaft Obere Industriestrae 8
see Coolant / lubricant preparation 3.11 D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
3.12 Air extraction systems Fax: +49 (0) 2738 / 21-503
Abluft-Systeme E-Mail: metals@siemag.com
Internet: www.siemag.com
Exhaust air purification
systems (active) Vollert GmbH + Co. KG
Abluft-Reinigungssysteme (aktiv)
Anlagenbau
see Transport of finished anode elements
to the pot room 1.4
Achenbach Buschhtten GmbH
Siegener Str. 152, D-57223 Kreuztal 3.17 Strip Processing Lines
Tel. +49 (0) 2732/7990, info@achenbach.de Bandprozesslinien
Internet: www.achenbach.de
Strip Processing Lines
Bandprozesslinen
Bergwerk- und Walzwerk-
SMS Demag Aktiengesellschaft Maschinenbau GmbH
Eduard-Schloemann-Strae 4 Mercatorstrae 74 78
D-40237 Dsseldorf D-47051 Duisburg
Telefon: (0211) 8 81-0 Tel.: +49 (0) 203-9929-0
Telefax: (0211) 8 81-49 02 Fax: +49 (0) 203-9929-400
Internet: http://www.sms-demag.com E-Mail: bwg@bwg-online.de
E-Mail: communications@sms-demag.com Internet: www.bwg-online.com
Geschftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstrae 30
D-57271 Hilchenbach-Dahlbruch Colour Coating Lines
Telefon: (02733) 29-0 Bandlackierlinien
Telefax: (02733) 29-28 52
Bandanlagen
Walderstrae 51/53
D-40724 Hilden www.bwg-online.com
Telefon: (0211) 8 81-5100 see Strip Processing Lines 3.17
Telefax: (0211) 8 81-5200
Filtering plants and systems Strip Annealing Lines
Filteranlagen und Systeme
Bandglhlinien
www.bwg-online.com
see Strip Processing Lines 3.17
Dantherm Filtration GmbH
Industriestr. 9, D-77948 Friesenheim
Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 Stretch Levelling Lines
E-Mail: info.de@danthermfiltration.com Streckrichtanlagen
Internet: www.danthermfiltration.com
3.14 Storage and dispatch www.bwg-online.com
Lagerung und Versand see Strip Processing Lines 3.17
Lithographic Sheet Lines
SIEMAG GmbH Lithografielinien
Obere Industriestrae 8
D-57250 Netphen
Tel.: +49 (0) 2738 / 21-0
Fax: +49 (0) 2738 / 21-503
E-Mail: metals@siemag.com www.bwg-online.com
Internet: www.siemag.com see Strip Processing Lines 3.17
ALUMINIUM 1-2/2007
 Lieferverzeichnis

Foundry
4
4.1
Gieerei
Work protection and ergonomics 4.1 Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology 4.2 Feuerfesttechnik
4.3 Conveyor and storage technology 4.3 Frder- und Lagertechnik
4.4 Mould and core production 4.4 Form- und Kernherstellung
4.5 Mould accessories and accessory materials 4.5 Formzubehr, Hilfsmittel
4.6 Foundry equipment 4.6 Gieereianlagen
4.7 Casting machines and equipment 4.7 Giemaschinen und Gieeinrichtungen
4.8 Handling technology 4.8 Handhabungstechnik
4.9 Construction and design 4.9 Konstruktion und Design
4.10 Measurement technology and materials testing 4.10 Messtechnik und Materialprfung
4.11 Metallic charge materials 4.11 Metallische Einsatzstoffe
4.12 Finshing of raw castings 4.12 Rohgussnachbehandlung
4.13 Melt operations 4.13 Schmelzbetrieb
4.14 Melt preparation 4.14 Schmelzvorbereitung
4.15 Melt treatment devices 4.15 Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology 4.16 Steuerungs- und Regelungstechnik
4.17 Environment protection and disposal 4.17 Umweltschutz und Entsorgung
4.18 Dross recovery 4.18 Schlackenrckgewinnung

4.2 Heat-resistent technology 4.6 Foundry equipment Tolls for the foundry
Gieerei-Werkzeuge
Feuerfesttechnik Gieereianlagen
Refractories Cast-Tec GmbH & Co. KG Albert Turk GmbH & Co. KG
Feuerfeststoffe Fertigungstechnik & Service D-58540 Meinerzhagen,
D-44536 Lnen, Brunnenstrae 138 Tel. 02358/2727-0, Fax 02358/2727-27
Silca Service- und Vertriebsgesellschaft Telefon: 02306/20310-0
fr Dmmstoffe mbH Telefax: 02306/20310-11
Auf dem Hls 6, D-40822 Mettmann E-Mail: Info@cast-tec.de Casting machines
Tel. 02104/97270, Fax 02104/76902 Internet: www.cast-tec.de Giemaschinen
E-Mail: info@silca-online.de
Internet: www.silca-online.de

Promat GmbH Techn. Wrmedmmung

Scheifenkamp 16, D-40878 Ratingen THERMCON OVENS BV
Tel. +49 (0) 2102 / 493-0, Fax -493 115 see Extrusion 2
verkauf3@promat.de, www.promat.de

Casting launder linings Planning HERTWICH ENGINEERING GmbH

Gierinnenauskleidungen
Silca Service- und Vertriebsgesellschaft
fr Dmmstoffe mbH
Auf dem Hls 6, D-40822 Mettmann
Tel. 02104/97270, Fax 02104/76902
E-Mail: info@silca-online.de
Internet: www.silca-online.de
4.3 Conveyor and storage
technology
Frder- und Lagertechnik
Vollert GmbH + Co. KG
Anlagenbau
see Transport of finished anode elements
to the pot room 1.4
Projektierung Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstrae 6, A-5280 Braunau am Inn
see Equipment and accessories 2.11
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com Solution annealing furnaces/plant
Lsungsglhfen/anlagen
Construction
Bau

4.5 Mold accessories and ERNST REINHARDT GMBH

accessory materials Postfach 1880, D-78008 VS-Villingen
Formzubehr, Hilfmittel Tel. 07721/8441-0, Fax 8441-44
E-Mail: info@ernstreinhardt.de
Fluxes Internet: www.Ernst-Reinhardt.com
Flussmittel
HERTWICH ENGINEERING GmbH Heat treatment furnaces
Solvay Fluor GmbH Maschinen und Industrieanlagen
Hans-Bckler-Allee 20 Weinbergerstrae 6, A-5280 Braunau am Inn Wrmebehandlungsfen
D-30173 Hannover Phone +437722/806-0
Telefon +49 (0) 511 / 857-0 Fax +437722/806-122
Telefax +49 (0) 511 / 857-2146 E-Mail: info@hertwich.com
Internet: www.solvay-fluor.de Internet: www.hertwich.com see Foundry equipment 4.6

ALUMINIUM 1-2/2007 125

Lieferverzeichnis

4.7 Casting machines 4.11 Metallic charge 4.13 Melt operations

and equipment materials Schmelzbetrieb
Gieereimaschinen Metallische Einsatzstoffe
und Gieeinrichtungen

OTTO JUNKER GmbH

THERMCON OVENS BV
see Extrusion 2
OTTO JUNKER GmbH
THERMCON OVENS BV
see Extrusion 2 Scholz AG Melting furnaces
Am Bahnhof Schmelzfen
D-73457 Essingen
Tel. +49 (0) 7365-84-0
Molten Metall Level Control Fax +49 (0) 7365-1481
Ostra Hamnen 7 E-Mail: infoscholz@scholz-ag.de Bttgenbachstrae 14
SE-430 91 Hono / Schweden Internet: www.scholz-ag.de D-40549 Dsseldorf/Germany
Tel.: +46 31 764 5520 Tel.: +49 (0) 211 / 5 00 91-43
Fax: +46 31 764 5529 Fax: +49 (0) 211 / 50 13 97
E-mail: sales@precimeter.se Aluminium alloys E-Mail: info@bloomeng.de
Internet: www.precimeter.se Aluminiumlegierungen Internet: www.bloomeng.com
Sales Contact: Rolf Backberg Sales Contact: Klaus Rixen

Mould parting agents

Kokillentrennmittel
Schrder KG
Schmierstofftechnik
Postfach 1170
D-57251 HERTWICH ENGINEERING GmbH
Freudenberg METALLHTTENWERKE BRUCH GMBH
Maschinen und Industrieanlagen
Postfach 10 06 29
Tel. 02734/7071 Weinbergerstrae 6, A-5280 Braunau am Inn
D-44006 Dortmund
Fax 02734/20784 Phone +437722/806-0
Telefon +49 (0) 231 / 8 59 81-121
www.schroeder-schmierstoffe.de Fax +437722/806-122
Telefax +49 (0) 231 / 8 59 81-124
E-Mail: info@hertwich.com
E-Mail: al-vertrieb@bruch.de
Internet: www.hertwich.com
Internet: www.bruch.de
4.8 Handling technology
Handhabungstechnik
METALLHANDELSGESELLSCHAFT
SCHOOF & HASLACHER MBH & CO. KG
Postfach 600714, D 81207 Mnchen
see Equipment and accessories 2.11
Telefon 089/829133-0
Telefax 089/8201154
THERMCON OVENS BV E-Mail: info@metallhandelsgesellschaft.de
see Extrusion 2 Internet: www.metallhandelsgesellschaft.de
Vollert GmbH + Co. KG
Anlagenbau

see Transport of finished anode elements MARX GmbH & Co. KG

to the pot room 1.4 Lilienthalstr. 6-18
D-58638 Iserhohn
4.9 Construction and Tel.: +49 (0) 2371 / 2105-0, Fax: -11
Design E-Mail: info@marx-gmbh.de
ALERIS Recycling (German Works) GmbH Internet: www.marx-gmbh.de
Konstruktion und Design
Aluminiumstrae 3
D-41515 Grevenbroich
Telefon +49 (0) 2181/16 45 0 maerz-gautschi
Telefax +49 (0) 2181/16 45 100 Industrieofenanlagen GmbH
see Casting Equipment 3.1
E-Mail: recycling@aleris.com
THERMCON OVENS BV Internet: www.aleris-recycling.com
see Extrusion 2 Holding furnaces
Warmhaltefen
4.10 Measurement Pre alloys
technology and Vorlegierungen
materials testing
Messtechnik und METALLHANDELSGESELLSCHAFT Bttgenbachstrae 14
SCHOOF & HASLACHER MBH & CO. KG D-40549 Dsseldorf/Germany
Materialprfung Postfach 600714, D 81207 Mnchen Tel.: +49 (0) 211 / 5 00 91-43
Telefon 089/829133-0 Fax: +49 (0) 211 / 50 13 97
SRS Amsterdam BV Telefax 089/8201154 E-Mail: info@bloomeng.de
www.srsamsterdam.com E-Mail: info@metallhandelsgesellschaft.de Internet: www.bloomeng.com
see Casthouse (foundry) 1.5 Internet: www.metallhandelsgesellschaft.de Sales Contact: Klaus Rixen

126 ALUMINIUM 1-2/2007

 Lieferverzeichnis

4.14 Melt preparation 4.16 Control and

Schmelzvorbereitung regulation technology
Steuerungs- und
see Equipment and accessories 2.11 Regelungstechnik

maerz-gautschi HCL measurements

Industrieofenanlagen GmbH OTTO JUNKER GmbH HCL Messungen
see Casting Equipment 3.1 THERMCON OVENS BV
see Extrusion 2
OPSIS AB
Box 244, S-24402 Furulund, Schweden
Heat treatment furnaces Tel. +46 (0) 46-72 25 00, Fax -72 25 01
Wrmebehandlungsanlagen Degassing, filtration E-Mail: info@opsis.se
Entgasung, Filtration Internet: www.opsis.se

maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1 4.17 Environment protec
tion and disposal
Drache Umwelttechnik Umweltschutz und
HERTWICH ENGINEERING GmbH GmbH Entsorgung
Maschinen und Industrieanlagen Werner-v.-Siemens-Strae 9/24-26
Weinbergerstrae 6, A-5280 Braunau am Inn D 65582 Diez/Lahn
Phone +437722/806-0 Telefon 06432/607-0
Fax +437722/806-122 Telefax 06432/607-52 Dust removal / Entstaubung
E-Mail: info@hertwich.com Internet: http://www.drache-gmbh.de
Internet: www.hertwich.com
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
info@neotechnik.com, www.neotechnik.com

IUT Industriell Ugnsteknik AB HERTWICH ENGINEERING GmbH

Industrivgen 2, 43892 Hrryda, Sweden Flue gas cleaning
Maschinen und Industrieanlagen Rauchgasreinigung
Tel. +46 (0) 301 31510 Weinbergerstrae 6, A-5280 Braunau am Inn
Fax +46 (0) 301 30479 Phone +437722/806-0
E-Mail: office@iut.se Fax +437722/806-122
Internet: www.iut.se E-Mail: info@hertwich.com
Internet: www.hertwich.com

Dantherm Filtration GmbH

see Equipment and accessories 2.11
maerz-gautschi
Industrieofenanlagen GmbH
see Casting Equipment 3.1
Heat treatment technologies
Wrmebehandlungsverfahren
Wrmebehandlungstechnologien
Melt treatment agents Industriestr. 9, D-77948 Friesenheim
Schmelzebehandlungsmittel Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245
E-Mail: info.de@danthermfiltration.com
maerz-gautschi Internet: www.danthermfiltration.com
Industrieofenanlagen GmbH
see Casting Equipment 3.1
4.18 Dross recovery
Schlackenrckgewinnung
4.15 Melt treatment devices
Schmelzbehandlungs-
einrichtungen
OTTO JUNKER GmbH
THERMCON OVENS BV
see Extrusion 2

OTTO JUNKER GmbH

THERMCON OVENS BV
see Extrusion 2
Do you need
ALUTEC-BELTE AG, ALUMINIUMTECHNOLOGIE Metaullics Systems Europe B.V.
Lindenweg 5 P.O.Box 748 more information?
D-33129 Delbrck NL-2920 CA Krimpen a/d Yssel
Tel.: +49 (0 ) 52 50 / 98 79-0 Tel. +31-180/590890
Fax: +49 (0 ) 52 50 / 98 79-149 Fax +31-180/551040 E-Mail:
E-Mail: info@alutec-belte.com E-Mail: info@metaullics.nl Schwichtenberg@giesel.de
Web: www.alutec-belte.com Internet: www.metaullics.com

ALUMINIUM 1-2/2007 127

Lieferverzeichnis

Materials and Recycling Thermal coating

5 Werkstoffe und Recycling

Aluminium foam Granulated aluminium
Thermische Beschichtung
Berolina Metallspritztechnik
Wesnigk GmbH
Pappelhain 30
D-15378 Hennickendorf
Aluminiumschaum Aluminiumgranulate
Tel.: +49 (0) 33434 / 46060
Fax: +49 (0) 33434 / 46701
E-Mail: info@metallspritztechnik.de
Internet: www.metallspritztechnik.de

6.2 Semi products

Alulight International GmbH
Lach 22
A-5282 Ranshofen
Telefon ++43 / 7722 / 62216-26
Telefax ++43 / 7722 / 62216-11
E-Mail: office@alulight.com
Internet: www.alulight.com
ECKA Granulate Austria GmbH
Brmooser Landesstrae 19
A-5113 St. Georgen/Salzburg
Telefon +43 7722 62216-41
Telefax +43 7722 62216-44
Kontakt: Walter Rajner
E-Mail: w.rajner@ecka-granules.com
Halbzeuge
Wires / Drhte
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
E-Mail: info@elisental.de
Internet: www.elisental.de

Machining and Application

6 Bearbeitung und Anwendung
Machining of aluminium Paint stripping / Entlackung
6.3 Equipment for forging
and impact extrusion
Ausrstung fr Schmiede-
und Fliepresstechnik
Aluminiumbearbeitung Hydraulic Presses
Henkel KGaA Hydraulische Pressen
Haarmann Holding GmbH see Prozesse fr die Oberflchentechnik 6.1
see Die preparation and care 2.6
Pretreatment before coating
Vorbehandlung vor der Beschichtung
LASCO Umformtechnik GmbH
6.1 Surface treatment Hahnweg 139, D-96450 Coburg
processes Henkel KGaA Tel. +49 (0) 9561 642-0
see Prozesse fr die Oberflchentechnik 6.1 Fax +49 (0) 9561 642-333
Prozesse fr die E-Mail: lasco@lasco.de
Oberflchenbehandlung Joining of light metals Internet: www.lasco.com
Fgen von Leichtmetallen
Literature
Henkel KGaA
8 Literatur
Technikcal literature
Fachliteratur
D-40191 Dsseldorf
Tel. +49 (0) 211 / 797-30 00 Henkel KGaA Taschenbuch des Metallhandels
Fax +49 (0) 211 / 798-36 36 Standort Heidelberg
Hans-Bunte-Strae 4 Fundamentals of Extrusion Technology
Internet: www.henkel-technologies.com Giesel Verlag GmbH
D-69123 Heidelberg
Tel. +49 (0) 6221 / 704-204 Verlag fr Fachmedien
Adhesive bonding / Verkleben Fax +49 (0) 6221 / 704-515 Ein Unternehmen der Klett-Gruppe
Rehkamp 3 30916 Isernhagen
Pretreatment before Tel. 0511 / 73 04-122 Fax 0511 / 73 04-157
Henkel KGaA adhesive bonding
see Prozesse fr die Oberflchentechnik 6.1
Vorbehandlung vor dem Verkleben Technical journals
Fachzeitschriften
Anodising / Anodisation
Henkel KGaA
see Prozesse fr die Oberflchentechnik 6.1
Henkel KGaA International Journal for Industry, Research and Application
see Prozesse fr die Oberflchentechnik 6.1
Spectrocolor Interferencecolouring
Spectrocolor Interferenzfrben
Cleaning / Reinigung

Henkel KGaA Henkel KGaA

see Prozesse fr die Oberflchentechnik 6.1
Joining / Fgen
Henkel KGaA
see Prozesse fr die Oberflchentechnik 6.1
see Prozesse fr die Oberflchentechnik 6.1
Waste water treatment
Abwasseraufbereitung
Giesel Verlag GmbH
Ein Unternehmen der Klett-Gruppe
Henkel KGaA Rehkamp 3 30916 Isernhagen
see Prozesse fr die Oberflchentechnik 6.1 Tel. 0511 / 73 04-122 Fax 0511 / 73 04-157

128 ALUMINIUM 1-2/2007


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Tel: +33 (0)1 47 30 71 80,
Fax: +33 (0)1 47 30 01 89
E-Mail: achrismann@wanadoo.fr
129
VORSCHAU / PREVIEW

Im nchsten Heft

Special: Aluminium-Recycling
berblick ber die Sekundraluminiumindustrie
weltweit
Schmelz- und Gietechnik: Innovative Anlagen
von Ausrstern, konstruktive Anforderungen an
die Anlagenmodernisierung, Schmelzebehandlung
Unterschiedliche Recyclinganstze in Umwelt-
analysen und ihre Konsequenzen Forschung:
Entwicklung neuer Duktilittskriterien von Leicht-
Aluminium im Automobil
bauwerkstoffen in der Fahrzeugentwicklung
Gietechnik im Motorenbau
Marktentwicklung der Automobilindustrie und des Weitere Themen
Leichtmetalls Aluminium Aktuelles aus der Branche - Httentechnik - An-
wendungen
Economics
Wertanalyse im Downstreamgeschft der Alu-
miniumindustrie Erscheinungstermin: 5. Mrz 2007
Anzeigenschluss: 16. Februar 2007
Redaktionsschluss: 2. Februar 2007

In the next issue Research

Potentials of new ductility criterions in car devel-
Special: Aluminium recycling opment with lightweight materials
Overview of the global secondary aluminium
Other topics
industry
Latest news from the industry
Melting and casting technology: innovative plants
from suppliers, design requirements for plant mod- Smelting technology
ernisation, melt treatment Applications
Different recycling approaches in environment
analyses and their consequences

Automotive
Casting technology for engines
Market development in the car industry and of the
lightweight metal

Economics
The value engineering in downstream sectors of
modern aluminium industry Day of publication: 5 March 2007
Advertisement deadline: 16 February 2007
Editorial deadline: 12 February 2007

130 ALUMINIUM 1-2/2007

Simply closer to
your products.
Visit us at
METEC 2007
Hall 6, Booth E20
June 12 to 16 in Dsseldorf,
Germany

Your technology partner in the aluminum industry.

How do we meet the growing demands of our cus-
tomers in the aluminum industry worldwide? By sup-
plying all-inclusive mechatronic solutions. Whatever
you want to manufacture from this material, or what
product quality you aim to achieve at SMS Demag
we know what it takes. Thats because we listen!
And because we draw on our holistic process know-
how and experience. Our plants whether new facili-
ties, conversions or revamps always ensure that our
solutions encompass the latest developments in alu-
minum production and processing.
Always closer to you SMS Demag.

MEETING your EXPECTATIONS

SMS DEMAG AG
Eduard-Schloemann-Strasse 4 Phone: +49 (0) 211 881-0 E-mail: communications@sms-demag.com
40237 Dsseldorf, Germany Fax: +49 (0) 211 881-4902 Internet: www.sms-demag.com
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