Volume 86 · March 2010 International Journal for Industry, Research

Special 2010: The aluminium recycling industry Dubal celebrates major production milestone A busy time in the Danieli Fröhling workshop Interview mit Thomas Reuther über das Recyclinggeschäft der Trimet

Trimet

Giesel Verlag GmbH · Postfach 120158 · D-30907 Isernhagen · www.alu-web.de – PVST H 13410 – Dt. Post AG – Entgelt bezahlt

OFFICIAL INTERNATIONAL MEDIA PARTNER

Volume 86 · March 2010 International Journal for Industry, Research and Application

3

HE-ECOMELT-PP State-of-the-art Chip Melting

Leading technology in the aluminum casthouse. There are many benefits in one-stop-shopping of industrial goods. At Hertwich Engineering we provide customer oriented service throughout the project duration and service life of equipment. We design and build plants to meet both, our own stringent standards and individual customers specifications. Based on many years of experience, we cover the full range of equipment in a modern aluminum casthouse. Major benefits Hertwich Engineering is well-known for leading edge technology. Our valued customers deserve to get the best value for money. Commitment to innovation, solid engineering and own R&D are instrumental for staying ahead with continuous improvements and new products.

HE-Ecomelt-PP60 PP = Preheat Pipe for high-speed co-flow drying Melting system for remelting swarf and chips with possible adherent water, oil or emulsion Melting capacity 3 t / h or 60 t /day Extremely low melt loss (< 1 %), thus high metal recovery Very low specific energy consumption (< 550 kWh/t inclusive drying) Good metal quality of the melt (low oxide and hydrogen content) Low manpower for operation and maintenance Meeting most stringent environmental standards

MEETING your EXPECTATIONS HERTWICH ENGINEERING GMBH

Weinbergerstrasse 6 5280 Braunau, Austria

Phone: +43 (0) 7722 806-0 Fax: +43 (0) 7722 806-122

E-mail: [email protected] Internet: www.hertwich.com

eDitoRial

Volker Karow Chefredakteur Editor in Chief

Die Recyclingbranche vor gravierenden Herausforderungen

Recycling industry faced by serious challenges

ALUMINIUM · 3/2010

Die Aluminiumrecyclingbranche in Europa hat ein sehr schwieriges Jahr hinter sich. Die Produktion von Gusslegierungen brach im vergangenen Jahr drastisch ein, weil sie zu rund 75 bis 80 Prozent vom Wohl und Wehe der Automobilindustrie abhängt. Viele Betriebe mussten Insolvenz anmelden, weil sie mit einer dünnen Eigenkapitaldecke und geringen Reserven ausgestattet sind, die das Überdauern einer Durststrecke schwierig machen. Die Banken sind zudem sehr zurückhaltend bei der Finanzierung von Umlaufvermögen; Kredite werden, wenn überhaupt, nur zu harten Konditionen vergeben. Inzwischen weisen die monatlichen Produktionszahlen für Sekundäraluminium wieder positive Vorzeichen zum Vorjahreszeitraum auf, aber die grundsätzlichen Probleme der mittelständisch strukturierten Industrie sind damit längst nicht gelöst. Die Branche braucht Konsolidierung. Die Anforderungen seitens der Autohersteller an die Entwicklung von Sekundärlegierungen werden steigen. Das verlangt entsprechendes F&E-Knowhow bei den Umschmelzern, das in kleinen Betrieben nicht vorhanden ist. Hinzu kommt, dass Knetlegierungen im Automobil wachsende Bedeutung erlangen. Bei den langen Produktzyklen eines PkwModells sind die Automobilhersteller vermehrt an Partnerschaften mit Zulieferern auf der Gießerei- und Umschmelzseite interessiert, von denen man erwarten kann, dass sie auch in zehn Jahren noch am Markt sein werden. Bei alledem ist nicht zu vergessen, dass der westeuropäische Automobilmarkt gesättigt ist und das dynamische Nachfragewachstum in den Schwellenländern stattfindet. Das wird langfristig zu Produktionsverschiebungen führen, die die Gießerei- und Recyclingbranche massiv berühren werden. Diesen marktorientierten Herausforderungen stehen die umweltpolitischen zu Seite. Noch immer ist offen, inwieweit Brüssel Ausnahmeregelungen beim Emissionshandel ab 2013 für die Recyclingbranche gewährt. Die wären nur logisch und konsequent in einem Europa, das sich im Umwelt- und Klimaschutz an die Spitze der Welt setzen will. Aber wann geht es in der Politik schon logisch und konsequent zu?

The aluminium recycling sector in Europe has come through an extremely difficult year. In 2009 the production of casting alloys fell drastically, since it depends to an extent of 75 to 80 percent on the wellbeing and woes of the automobile industry. Many companies had to declare insolvency because their slim equity position and low reserves made it impossible to survive in so hard an environment. Besides, the banks were very reluctant to finance working capital; when credit was available at all, it was only granted subject to stringent conditions. Since then monthly production figures have improved again compared with those of last year, but the fundamental problems of the recycling industry with its medium-sized corporate structure are still far from solved. Consolidation is needed in the sector. Requirements on the part of automobile manufacturers relating to the development of secondary alloys are becoming stricter, and this demands corresponding levels of research and development know-how from remelters which are not in place in small companies. Another factor is that in automotive engineering wrought alloys are gaining importance. Over the long product cycles of a passenger car model car makers are increasingly interested in partnerships with suppliers on the foundry and remelting side who can be expected still to be in business in ten years. On top of all that, it must be remembered that the automobile market in Western Europe is virtually saturated; nowadays, dynamic demand growth takes place in the developing countries. In the long term that will result in production relocations which will have a massive effect on the foundry and recycling industry. These market-orientated challenges are compounded by environment policy issues. It is still an open question how far Brussels will go toward providing support for the recycling sector with exemption regulations on emissions trading from 2013 onwards. That would be no more than logical and consistent in a Europe which wants to lead the world in the field of environment and climate protection. But how often do logic and consistency find their way into politics?



i N H a lt

eDitoRial Die Recyclingbranche vor gravieren den Herausforderungen ............ 

a Kt U e l l e S Personen, Unternehmen, Märkte ..................................... ....... 6

WiRtSCHaFt

14

Englischsprachige Artikel: s. nebenstehendes Verzeichnis Aluminiumpreise ......................................................... ..... 10 Produktionsdaten der deutschen Aluminiumindustrie .................. 12 Druckgussindustrie sieht Chancen für zweistelliges Wachstum 2010 20

SPeCial: alUMiNiUMReCYCliNGiNDUStRie Englischsprachige Artikel: s. nebenstehendes Verzeichnis VAR-Vorsitzender Oetinger zu Aluminiumschrottexporten nach China: „Klimatische Entwicklungshilfe gefährdet Versorgung in Europa“ .... 24

28

Gutachten im Auftrag der Scholz Aluminium GmbH: CO 2 -Emission der Sekundärroute beträgt nur vier Prozent der Primärroute ....................................................... 25 Interview mit Thomas Reuther, Vorstandsmitglied der Trimet: „Wir bieten die klassischen Stärken des Mittelstandes: kurze Entscheidungswege, gesunde Finanzstruktur, marktnahes Management“ ...... 

t e CH N o lo G i e Englischsprachige Artikel: s. nebenstehendes Verzeichnis Hochbetrieb in der Werkstatt von Danieli Fröhling: Das Krisenjahr 2009 gut gemeistert ....................................... 4



i N t e R N at i o N a l e B R a N C H e N N e W S ................... 49

R e S e a R C H ........................................................... ..... 55 Englischsprachige Artikel: s. nebenstehendes Verzeichnis

D o K U M e N tat i o N Bücher .......................................................................... 60

8

Patente ......................................................................... 60 Impressum ..................................................................... 81 Vorschau........................................................................ 82

Der ALUMINIUM-Branchentreff des Giesel Verlags: www.alu-web.de

4

B e Z U G S Q U e l l e N V e R Z e i C H N i S ....................... ..... 6

ALUMINIUM · 3/2010

CONTENTS

EDITORIAL Recycling industry faced by serious challenges ............................ 3

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

ECONOMICS

43

Bauxite and alumina activities in 2009, Part I ........................... 14 Dubal celebrates major production milestone ........................... 17 Emal delivers to first local customer . . . .................................... 18 Die casting industry expects double-digit growth in 2010 ............. 20

SPECIAL: ALUMINIUM RECYCLING INDUSTRY Scrap exports to China threaten supplies in Europe in the long term 27 Secondary aluminium smelting activities in 2009 ....................... 28 T. T. Tomorrow Technology celebrates its 10 th anniversary ............. 38 Remelting and refining modes in advanced recycling of wrought aluminium alloys, Part I . . . . . . . ................................... 39

47

T E CH N O LO GY A busy time in the Danieli Fröhling workshop: The crisis year 2009 overcome well . . . .................................... 43 Technology breakthrough in the production of aluminium ingots .... 47

C O M PA N Y N E W S W O R L D W I D E Aluminium smelting industry . . . . . . . . . . . .................................... 49 Bauxite and alumina activities . . . . . . . . . . .................................... 50 Recycling and secondary smelting . . . . . .................................... 51 Aluminium semis . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 52

Inserenten dieser Ausgabe

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

List of advertisers

Suppliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 54

ABB Automation Technologies, Sweden Buss AG, Schweiz Coiltec Maschinenvertriebs GmbH Danieli Fröhling Josef Fröhling GmbH & Co. KG Drache Umwelttechnik GmbH F. W. Brökelmann Aluminiumwerk GmbH & Co. KG Hertwich Engineering GmbH, Österreich LOI Thermprocess GmbH Inotherm Industrieofen- und Wärmetechnik GmbH Meed Middle East Business Intelligence Reed Exhibitions Deutschland GmbH Shanghai Jieru, PRC SMS Siemag AG Zhengzhou Zhongshi Cell Technology Co., Ltd, PRC

RESEARCH Innovative joining methods for lightweight designs, Part II .......... 55

D O C U M E N TAT I O N Imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 81 Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... 82

S O U R C E O F S U P P LY L I S T I N G ............................... 63

ALUMINIUM · 3/2010

29 31 53 45 15 37 2 23 16 19 35 13 84 11

5

Aktuelles

Achenbach liefert Folienwalzlinie nach China

0 Jahre: Axel e. Barten

Vertragsunterzeichnung für eine weitere Gesamtanlage zur Folienproduktion: In den ersten Tagen des neuen Jahres 2010 hat das chinesische Un-

„Optiroll“-Automatisierungspaket, modernste Antriebstechnik und „Superstack II“-Filtrationsanlagen zur Walzölfeinstfiltration. Die Produkti-

Achenbach

Seit 1981 ist Dipl.-Ing. ETH Axel E. Barten Geschäftsführender Gesellschafter der Achenbach Buschhütten GmbH. Barten, der am 2. Dezember 2009 seinen 60. Geburtstag feierte, sieht sich als ein Glied in der langen Kette von Familieneigentümern des Unternehmens. Auch Barten hat Achenbach bis heute erfolgreich geführt und weiterentwickelt. Dies zeigt sich u. a. in der Verdreifachung des Firmenumsatzes, in der Erschließung neuer Absatzmärkte weltweit und im strukturellen Umbau des Unternehmens zu einem Hightech-Anlagenbauer: für NE-Metalle wie Aluminium, Kupfer, Zink und deren Legierungen, für die dazugehörenden Umweltschutzanlagen und für Schneid- und Wickelmaschinen für Feinband und Folie aus Aluminium. Bis heute ist Barten sehr stark an moderner Walzwerktechnik interessiert. Er ist davon überzeugt, dass herausragende Technik der Schlüsselfak-

ternehmen Luoyang Wanji Aluminium Processing den Auftrag zur Lieferung, Montage und Inbetriebnahme einer dreigerüstigen Folienwalzlinie für 2.000 mm breite Aluminiumbänder an Achenbach Buschhütten erteilt. Der Lieferumfang umfasst neben den drei Walzgerüsten das komplette

onsaufnahme ist für Ende 2011 geplant. Die Unterzeichner von links nach rechts: Thomas Kaup, Managing Director, Ferrostaal AG; Guo Feng, Executive General Manager, Luoyang Wanji Aluminium Processing; Rolf Wilbers, Executive Director Sales, Achenbach Buschhütten GmbH.

Achenbach

Zenergy Power und Bültmann mit BDI-Innovationspreis ausgezeichnet

tor im Geschäft mit Walzwerkanlagen ist. Barten engagiert sich in hohem Maße ehrenamtlich sowohl regional als auch fachgebunden in den entsprechenden Maschinenbauverbänden. Zudem gehörte er 1992 zu den Gründern des Fachverbandes „Hüttenund Walzwerkeinrichtungen“, ist dort seitdem im Vorstand, dessen Vorsitz er von 2001 bis 2009 innehatte. Die Redaktion ALUMINIUM gratuliert nachträglich zum Geburtstag.



Der Bundesverband der deutschen Industrie (BDI), hat den weltweit ersten Industriemaschinentyp in Supraleitertechnik mit dem Innovationspreis Klima und Umwelt ausgezeichnet. Es handelt sich bei dem Aggregat um einen hocheffizienten Magnetheizer für die Metallindustrie, der große Mengen elektrischer Energie einsparen hilft. Bundesumweltminister Norbert Röttgen und BDI-Hauptgeschäftsführer Werner Schnappauf überreichten den Preis in der Kategorie „Prozessinnovationen für den Klimaschutz“ in Berlin an die Zenergy Power GmbH und Bültmann GmbH, die diesen Maschinentyp gemeinsam entwickelt haben. Anders als normale elektrische Leiter übertragen Supraleiter Strom ohne Widerstand und daher auch ohne Verluste. Maschinen und Anlagen mit Supraleitertechnik sind dadurch leistungsfähiger und verbrau-

chen weniger Strom. Das erste Unternehmen, das den Anlagentyp seit 2008 in der Aluminiumverarbeitung einsetzt, spart damit 50 Prozent elektrische Energie ein und erzielt eine um 25 Prozent höhere Produktivität. Mit dem Magnetheizer stellen die Firmen Zenergy Power und Bültmann weltweit erstmals die Industrietauglichkeit der Supraleitertechnik unter Beweis. Aus Sicht der Industrie spricht für das Verfahren, dass die Erwärmung von Werkstoffen wie Aluminium oder Kupfer in einem Bruchteil der bisher üblichen Zeit abläuft und erstmals exakt gesteuert werden kann. Der Magnetheizer erwärmt ein breites Spektrum von Materialien und versorgt moderne Just-in-TimeFertigungen im flexiblen Wechsel mit Metallen verschiedener Zusammensetzungen. Mittlerweile wurden fünf Anlagen an europäische Kunden verkauft.

ALUMINIUM · 3/2010

News IN BrIeF

Hydro aims for global lead on reducing climate emissions After having already reduced direct emissions from primary production by 70% since 1990 – equal to a staggering three tonnes CO2-equivalents per tonne metal produced – Hydro aims to curb emissions even further and take global lead in the aluminium industry within the global fight against climate change. The renewed push to cut direct emissions from primary production is important not only from an environmental perspective as aluminium is set at 1.5 tonnes of CO2-equivalents per tonne metal produced. With free emission allowances for top performers when the new European emissions trading scheme (ETS) comes into force in 2013, there will be a strong incentive for industry players to reduce their carbon footprint and thereby reducing costs. In 2009, the average emission

level of CO2-equivalents from Hydro’s fully-owned Norwegian smelters at Sunndal, Årdal, Høyanger and Karmøy slipped just below two tonnes per tonne metal produced, down from around five tonnes in 1990 and 2.5 tonnes in 2000. With a total production from these smelters in 2009 of about 740,000 tonnes, this represents an annual reduction of 2.2 million

tonnes CO2-equivalents compared to the 1990-level, which is equal to taking one million cars off the road. The strong improvements have not only come through closures of outdated Søderberg lines, but also through systematic work to reduce anode effect and anode consumption.

rio tinto Alcan sees slow recovery of aluminium use Rio Tinto Alcan is cautiously optimistic about the economic recovery, but expects it will be three or four years before aluminium consumption rates return to pre-recession levels. The optimism is based on several factors, including rising consumer confidence, industrial output, construction levels and automotive production during the past three quarters. Urbanization and industrialization in countries like India, Brazil and China will assure long-term aluminium demand growth of about 4% per year during the next two decades.. But Rio Tinto Alcan has slowed major investments in Canada, including two smelters in Quebec and one in British Columbia valued at more than 6 billion Canadian dollars (USD5.7bn) due to the drop in aluminium prices. The company also will wait two or three more quarters to see where demand is headed before deciding whether spending will be ramped up, and it has no plan to make a significant restoration of the close to 10% of production capacity curtailed in 2009.

ALUMINIUM · 3/2010

Some uncertainty also remains over how robust the recovery will be once government stimulus packages around the world, which have helped boost demand and prices for aluminium, come to an end. In talks on big smelter project in Paraguay Rio Tinto Alcan and the Administratión Nacional de Electricidad (Ande) are negotiating the terms of a power purchase agreement for a po-

tential USD2.5bn aluminium smelter in Paraguay with a projected capacity of 485,000 tpy. Being built this would be one of the biggest industrial investments in Paraguay’s history. The smelter will only succeed if the company secures a cheap and guaranteed power supply to compensate for drawbacks at the site, such as lack of infrastructure, no sea access and no bauxite or alumina production. Construction could start in 2014 and put on stream in 2016. paw

Aluminium of Greece under eu scrutiny The EU Commission is investigating whether Greece’s state-owned Public Power Corp. (PPC) illegally subsidised Aluminium of Greece by selling electricity below market prices. PPC might have undercharged a total of 17.4m euros. The investigation comprises state-owned Public Gas Corp. which is confronted with the allegation of paying the construction costs of a gas pipeline belong-

ing to Aluminium of Greece. The European authority has already scrutinised complaints that the aluminium company received privileges before Greece joined the EU in 1981. In July 2009, PPC sought arbitration to resolve a dispute with Aluminium of Greece, which refused to accept a 10% increase in PPC’s electricity prices, citing profitability concerns amid a slumping metals market.



Aktuelles

Industriestrompreise weiter gefallen VIk-strompreisindex Mittelspannung

Der VIK-Index ist im Januar 2010 gegenüber dem Vormonat um 5,89 Punkte (-3,95%) gefallen und liegt aktuell bei 143,39 Punkten. Die Veränderung ist auch in diesem Monat wieder auf die im Durchschnitt (Mittelwert bei 3.000, 4.000, 5000 und 6.000 Jahresbenutzungsstunden) gegenüber dem Vormonat um 2,74 €/MWh (-5,42%) gesunkenen Strompreise an der EEX für die folgenden vier Quartale 2010 zurückzuführen. Maßgeblich ist der Handelsmonat Dezember 2009.

Sowohl der Verband der Industriellen Energie- und Kraftwirtschaft (VIK) als auch der Bundesverbandes der Energie-Abnehmer (VEA) melden gesun-

kene Strompreise für die Industrie. Wegen der stark gesunkenen Großhandelspreise für Strom können mittelständische Unternehmen derzeit

VAr / OeA-Druckguss-wettbewerb 2010

VAR / OEA

Der deutsche und der europäische Verband der Recyclingindustrie VAR und OEA haben mit Unterstützung des Bundesverbandes der Deutschen Gießerei-Industrie (BDG) erneut ei-

Preisträger „Türrahmen Porsche G1 Pana­ mera“. Bei diesem Gussteil handelt es sich um die erste Serienanwendung, bei der präzise Außengeometrien durch einen La­ serschneidprozess erstellt werden. Dieses Verfahren führt gegenüber konventionell gestanzten Gussteilen zu einer deutlichen Qualitätsverbesserung.

nen Aluminium-Druckguss-Wettbewerb durchgeführt. Alle zur Bewertung vorliegenden Druckgussteile zeichneten sich durch eine hohe Prä-



zision in der Herstellung, beste druckgießgerechte Konstruktion und hohe Gussqualität aus. Vergeben wurden je zwei erste Preise und je ein zweiter Preis in der Kategorie „Strukturteile“ und „Multifunktionale endkonturnah gegossene Teile“. Preisträger in der Kategorie „Strukturteile“ sind der Heckklappentragrahmen BMW 5er Gran Turismo der BMW-Leichtmetallgießerei in Landshut, außerdem der Türrahmen Porsche G1 Panamera, hergestellt von Georg Fischer im österreichischen Altenmarkt, sowie das Verbindungsteil Schweller-Längsträger rechts Audi A8 aus dem VW-Werk in Kassel. Preisträger in der Kategorie „Multifunktionale endkonturnah gegossene Teile“ sind das Fluidmanagement-Ölfiltersystem für Deutz-Motoren der Gießerei Hengst aus Nordwalde, außerdem die Elektronische Luftaufbereitung der DGS Druckguss Systeme aus St. Gallen in der Schweiz sowie der Wärmetauscher für gasbefeuerte Heizkessel von Rubitech Heating aus Steenwijk, Niederlande.

günstige Lieferverträge abschließen, so der VEA. Deren aktueller Strompreisvergleich ermittelt eine durchschnittliche Preissenkung von knapp zehn Prozent im Vergleich zum Vorjahr. Die Entlastung hätte sogar höher ausfallen können, doch die Netzentgelte sowie die Förderung der erneuerbaren Energien haben einen Großteil des Preisrückgangs wieder aufgezehrt. Die Großhandelspreise gingen in den vergangenen zwölf Monaten um über 26 Prozent zurück. Gleichzeitig stiegen die Durchleitungskosten um sieben Prozent und die Umlage zur Förderung der erneuerbaren Energien um nahezu 80 Prozent. Der VEA rät allen Unternehmen zu einer bundesweiten Ausschreibung ihres Strombedarfs, um das aktuell günstige Marktumfeld zur Strombeschaffung für das Jahr 2011 zu nutzen. Der aktuelle VEA-Preisvergleich umfasst 50 große Netzgebiete in Deutschland. Am günstigsten ist der Strom in Kiel, am teuersten im Netzgebiet der E.ON Avacon in SachsenAnhalt. Nach wie vor ist der Preisunterschied zwischen den alten und neuen Bundesländern gravierend. In Ostdeutschland müssen Energieabnehmer durchschnittlich 7,8 Prozent mehr für Strom zahlen.

Auf ein wort „Wir müssen die Belastungen für bestimmte Branchen sehr genau im Auge behalten. Die Aluminiumindustrie befindet sich im Moment in einer schwierigen Lage. Ich will, dass Deutschland Industrieland bleibt. Dazu brauchen wir komplette Wertschöpfungsketten und auch die Aluminiumindustrie. “

Bundeswirtschaftsminister Rainer Brüderle im Handelsblatt, 18.01.2010

ALUMINIUM · 3/2010

News IN BrIeF

Reported primary aluminium production (Thousands of metric tonnes) Africa

North America

Latin America

East & South Asia

West Europe

East/Central Europe

Oceania

China

Total

5,495

2,275

2,475

4,068

3,996

2,198

5,547

27,482

Year

2003

1,428

Year

2005

1,753

5,382

2,391

3,139

4,352

4,194

2,252

7,806

31,269

Year

2007

1,815

5,642

2,558

3,717

4,305

4,460

2,315

12,588

37,400

Year

2009

1,681

4,759

2,508

4,401

3,722

4,117

2,211

12,964

36,363

IAI statistics show that world production of primary aluminium has increased by one third since 2003, despite production cuts due to the recent economic crisis. While output from the Americas and Europe has

remained more or less steady over the years, it is China and the Asian region that have expanded primary aluminium produc­ tion. With the start­up of the Qatalum plant and Emal smelter at the end of last year,

Aluminium due to surge

Novelis

The worldwide adoption of aluminium in industrial and consumer applications may be about to surge, says Philip Martens, president and chief operating officer of Novelis, a global leader in aluminium rolled products

Current projections of aluminium demand look too conservative, says Philip Martens

and aluminium can recycling. Mr Martens was the keynote speaker at the Platts Aluminium Symposium 2010 held early in February. Rapid urbanisation in developing countries and a push for sustainability are the drivers that will increase demand for aluminium beyond current projections. “Beverage cans, food packaging, appliances, construction, transportation and personal technology all are on the verge of a new boom in emerging markets. In transportation alone – products like shipping containers, trucks, commuter trains and

ALUMINIUM · 3/2010

automobiles – the opportunity is bigger than most observers have recognised”, he said. Light-weighting is the key. Without compromising strength, aluminium allows for light-weighting in the design of anything that moves. In a world constrained by fuel supplies, and as alternative energy sources come online, aluminium was the most plausible option, he said. According to market researcher Ducker Worldwide, the percentage of aluminium in automobile design has been gradually climbing for decades – from two percent in the United States in 1975 to a projected ten percent in 2020 – typically replacing steel components. But heightened consideration of light-weighting driven by consumer demand and government regulation could quickly change the pace of adoption. “We may be about to see a sharp turn in the next few years that would make the aluminium industry’s current projections of demand look very conservative”, Mr Martens told the Platts Aluminium Symposium. “We’ve been having talks with automobile manufacturers that are more than encouraging on this point.” Food packaging will see a new wave of demand as well, he is convinced. “In just the next few years, more than two billion people will cross the official threshold out of poverty. When you look at the global performance of beverage companies, it’s clear that the capacity to manufacture aluminium beverage containers and other food packaging will struggle to keep pace with demand.”

Source: IAI

Period

the Middle East – here included in ‘South Asia’ – will become even more important as an aluminium producer in future. Next year’s table will show a further rise in the ‘Asia’ column.

Aleris to emerge from Chapter 11 by mid-year Aleris International has filed its proposed plan of reorganisation (Plan) and related draft Disclosure Statement with the US Bankruptcy Court in Delaware. With this filing, Aleris and its wholly-owned US subsidiaries codebtors are positioned to emerge from Chapter 11 protection by mid-year. The Plan has support from Aleris’s creditors. “Since our filing last February, we have made significant improvements to our operations worldwide, reducing overhead, manufacturing costs and global headcount. When Aleris emerges from Chapter 11, we will have eliminated all of our term loan and unsecured debt and will have a strong balance sheet”, said Steven J. Demetriou, Aleris chairman and CEO. Key elements of the Plan, as currently proposed and subject to approval by the Bankruptcy Court, are among others: • The backstop parties have committed to invest up to USD690 million in the reorganised company, subject to customary conditions; • The reorganised company will emerge from chapter 11 as a privately held enterprise majority owned by existing creditors led by the backstop parties, which are the largest providers of the company’s debtor-in-possession (DIP) term loan financing; • Aleris will have a minimum of USD233 million of liquidity through cash and an anticipated USD500 million asset-backed revolving credit facility upon emergence.



wIrtsCHAFt

10

ALUMINIUM · 3/2010

CELL TECHNOLOGY

wIrtsCHAFt

Produktionsdaten der deutschen Aluminiumindustrie Primäraluminium

Sekundäraluminium

Walzprodukte > 0,2 mm

Press- & Ziehprodukte**

Produktion (in 1.000 t)

+/in % *

Produktion (in 1.000 t)

+/in % *

Produktion (in 1.000 t)

+/in % *

Produktion (in 1.000 t)

+/in % *

Dez

44,8

-14,1

28,8

-49,7

90,7

-23,8

23,2

-25,0

Jan 09

40,6

-23,1

40,3

-43,3

108,6

-29,6

34,4

-33,2

Feb

33,9

-31,3

36,7

-47,0

117,1

-26,5

31,8

-40,1

Mrz

27,5

-47,7

45,6

-29,0

133,2

-19,9

33,0

-31,9

Apr

17,5

-65,5

40,3

-45,6

121,3

-30,8

33,1

-40,1

Mai

17,5

-66,8

45,9

-29,7

120,0

-24,6

33,6

-29,1

Jun

18,2

-64,2

48,8

-28,7

135,8

-17,3

37,5

-30,1

Jul

19,9

-61,7

51,9

-17,0

149,1

-10,6

40,9

-23,6

Aug

20,5

-60,4

43,2

-12,5

132,0

-10,4

38,1

-23,1

Sep

21,2

-57,4

55,7

-10,0

140,9

-10,6

43,4

-16,0

Okt

24,2

-52,6

55,0

-4,9

143,8

-5,8

45,7

-9,3

Nov

24,5

-48,1

55,0

14,2

149,1

20,8

45,5

12,6

Dez

26,1

-41,6

42,4

47,3

109,3

20,5

26,9

15,9

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

Primäraluminium

walzprodukte > 0,2 mm

12

sekundäraluminium

Press- und Ziehprodukte

ALUMINIUM · 3/2010

Cold Rolling Mill

Slitter

YOUR RELIABLE PARTNER IN ALUMINIUM FABRICATION AND PROCESSING INDUSTRY!

economics

Bauxite and alumina activities in 2009, Part i R. P. Pawlek, Sierre This review covers the events during the year 2009. Due to the worldwide financial crisis, many new projects were delayed, while other projects were slowed down or abandoned. AFRicA

alumina are expected in five years. Ghana: In October, Rio Tinto sold its 80% stake in Ghana’s only bauxite mine to Chinese minerals group Bosai, which produces alumina and aluminium in China. Rio had earlier planned an integrated alumina refinery which would have been fed by the Awaso mine, but shelved this, as a result of poor local infrastructure and lower global demand for minerals. The mine in the West African country produced only 637,000 tonnes of bauxite in 2008. Guinea: Guinea’s bauxite mining and alumina refining operations

Cameroon: In May, Dubal’s Cameroon project was on track and is due to start production in 2013. In October Cameroon Alumina Ltd (CAL) had found 550m tonnes of bauxite at the Ngaoundal and Minim-Martap properties in the country’s Adamawa region, and there may be at least another 200m tonnes of first class bauxite which can be open pit mined. CAL is a joint venture set up in 2008 by Dubal and India’s Hindalco Industries, which each have a 45% stake, along with US firm Hydromine Inc. which holds the remaining interest. CAL hopes to build a mining operation at the site that would produce 4.5 to 9m tpy of bauxite starting in late 2014, and an alumina refinery with a capacity of 1.4 to 3m tpy. The real challenge is the logistics problem because the mining site is 860 km from the port. The key is to find an efficient and costeffective way of bringing processed alumina to the port for export. The company is in negotiations with government officials over possibly upgrading and extending existing Bauxite conveyance    railway links from the continue without disruption followmines to the Kribi deep sea port. This ing a military coup at the end of Dewould cost some USD5bn to build. If cember 2008 in the bauxite-rich west all goes according to plan, the bankaAfrican country. Nevertheless, there ble feasibility study should be through are still concerns about the new govin 2012 and make way for construcernment’s plans to push ahead with tion work to begin, which will last 40 a review of the country’s mining opmonths. First shipments of Cameroon

14

erations. There was some confusion over the status of the country’s mining contracts following comments by the head of the military, who is acting as Guinea’s new president, Captain Mousse Dadis Camara. Compagnie des Bauxites de Guinée (CBG), the country’s largest bauxite exporter, has not been affected by turbulence in the country, although Alcoa, a partner at the mine, continues to monitor the situation. In April, workers at Russian aluminium firm Rusal’s Friguia alumina refinery in Guinea began a strike for better salary. A reduced workforce kept a minimum service going, so the refinery did not shut down completely, but operated at a level of 40% of its productivity. Friguia can produce 640,000 tpy of alumina. Workers want the company to triple their salaries from USD100 to USD300 per month, a demand Rusal described as unacceptable and economically groundless. On 8 April, UC Rusal resumed full production at its alumina refinery in Guinea. In May, Global Alumina said it expected construction of its 3.6m tpy alumina refinery joint-venture project in Guinea to start within the next 18 months. Preliminary infrastructure is under construction at the Global Alumina site, while the company waits for the global economy to recover before seeking more credit to fund the building of the refinery. Photo: Alumar Partners in the project are BHP Billiton, Dubal and Middle Eastern investment company Mubadala. Political uncertainty in Guinea has not affected Global Alumina during the initial phases of the project and BHP’s Guinea alumina project has been delayed due to rising costs. Building of

ALUMINIUM · 3/2010

economics

the 3.6m tpy alumina refinery is due to start by the end of 2010. At the end of September, it was announced that Government revenues from Guinea’s CBG would fall some 60% in 2010 due to lower prices and export volumes. CBG exported a record 13.7m tonnes of bauxite in 2008, accounting for 80% of government mining income in the miningdependent nation. The revenues from CBG will go from USD101m in 2009 to USD38m in 2010. Alcoa and Rio Tinto Alcan control the Halco joint venture that owns 51% of CBG, and the Guinean government holds the remainder. CBG’s 2009 bauxite exports will only be around 11.3m tonnes, due to the global economic crisis. Guinea-Bissau: In May, Angolan company Bauxite Angola announced plans to build and manage a USD321m deep-water port in Buba, the largest city in southern Guinea-Bissau. The port is expected to become the gateway for Guinea-Bissau’s products. Angola Bauxite, partly owned by the Angolan state, is developing

a USD500m project to mine 3m tpy of bauxite in the Guinea-Bissau. The start-up date for the mine construction project and the port were not disclosed. Bauxite Angola will also build an alumina plant to process bauxite in Guinea-Bissau as well as a railway and a road linking Boe and Buba. THe AmeRicAs Brazil: At the end of January 2009 Novelis announced that it will cease the production of alumina at its Ouro Preto unit at the end of March. In future, the plant will purchase alumina through third-parties. Other activities related to the facility, including electric power generation and the production of primary aluminium, will continue unaffected. The Ouro Preto alumina facility is a small scale operation, primarily supplying the plant’s own requirements. Some 290 jobs will be removed at Ouro Preto. The remaining 800 jobs will continue to generate taxes and contribute to the economic and social development of

Spouts and Stoppers

Ouro Preto. In June, Brazilian alumina and aluminium producer Alumar expected to conclude its 2m tpy alumina expansion by the end of November 2009. Capacity is being increased to 3.5m tpy from the current 1.5m tpy, at a total investment of 5.1 billion reals (USD2.5bn). Recently, Alumar received equipment which will enable it to lift its seaport handling capability from 4.9m tpy to roughly 13m tpy. The company unloads bauxite and other raw materials in its port in São Luis, in Brazil’s northeastern state of Maranhão, and also ships from there its surplus alumina output that is not used to produce aluminium locally. In September, Alcoa commissioned its new bauxite operations in Juruti that are part of the Alcoa World Alumina and Chemicals (AWAC) joint venture with Alumina Ltd in which Alcoa holds a 60% share. They consist of a port facility, a mine and a 50 km rail system to the port. Initial output at the mine will ramp up to 2.6 m tpy. Bauxite from Juruti will ➝

Ceramic Foam Filters

C D C D m u i m n u i i min f or Alum c assttiinngg Drache

umwelttechnik

Drache Umwelttechnik GmbH · [email protected] ·

ALUMINIUM · 3/2010

www.drache-gmbh.de

15

economics

be shipped to the Alumar alumina refinery in São Luis. Following the expansion, Alcoa Aluminio and AWAC combined hold a 54 % share of the refinery. The remaining share is held by BHP Billiton (36%) and Rio Tinto Alcan (10%). The Alcoa share of the combined investment for the two Brazil initiatives is about USD2.2bn, and this will place Alcoa’s overall manufacturing system in the lower quartile on the global cost curve. The Juruti Project will mine – and re-vegetate – a total of 6,000 hectares

Advertisement

over a period of 40 to 60 years. For every Brazil nut tree removed during the mining process, Alcoa will replant ten trees. And for every other species of tree impacted during the process, Alcoa will replant two trees for each tree removed. In total, Alcoa estimates it will plant 15 million trees over the next 50 years in the Juruti region. Guyana: A strike over wages and job cuts stopped output at Guyana’s largest bauxite mine. Workers were resisting pressure by the company to accept 75 layoffs in return for a 10% wage increase for the remaining workers. The mine employs 500 people. Guyana, in South America, is the fourth largest supplier of bauxite to the United States. The strike at the Aroaima mine, 105 km south of the capital Georgetown, began on 22 November and there was no immediate end in sight. The current destructive actions by certain employees and unions are in violation of the collective labour agreement and labour discipline, and destabilise the situation among the company’s staff. Rusal bought the Aroaima operations from the government in 2004 through its local subsidiary Bauxite Company Guyana Inc. Rusal’s bauxite from Guyana supplies its Nikolaev alumina refinery in Ukraine, which produces up to 1.7m tpy of alumina.

16

Jamaica: In February, there was a meeting between Jamaican prime minister Bruce Golding and Chinese vice-president Xi Jinping, sparking rumours that Chinese aluminium producer Chinalco may be interested in alumina assets in the country. The Jamaican government is in discussions to sell its 45% stake in the 1.4m tpy Jamalco refinery in the country, in which Alcoa holds a 55% stake. But the two may also have discussed the future of Alumina Partners of Jamaica Ltd (Alpart), Rusal’s joint venture with Norsk Hydro. Chinalco could very well acquire Alpart, given the possibility of further production cuts at the operation. Alpart cut alumina production by 50% in January 2009 to 800,000 tpy and has put employees on a shorter working week. On 1 April, West Indies Alumina Co, whose majority shareholder is UC Rusal, suspended bauxite mining as part of a plan to temporarily shutter the Jamaican company’s operations. Windalco employs 1,119 people and produces 1.2m tpy of alumina at its two plants in Kirkvine in the south central region and Ewarton in the northeast. About 850 are affected by the suspension due to the world downturn in demand, but the company decided to keep them on the payroll working reduced hours on a reduced pay. Century Aluminum Co. announced the sale of the company’s 49% joint venture ownership positions in Gramercy Alumina LLC and St. Ann Bauxite Ltd to Noranda Aluminum Holding Corp. With the closing of this transaction on 31 August, Century has divested itself of its entire interest in the bauxite and alumina businesses. In November Noranda changed the name of its new bauxite operation from St. Ann Bauxite Ltd to Noranda Bauxite Ltd although the Jamaican government still owns 51%. Noranda Bauxite has a capacity to mine 4.8m tpy of bauxite but is expected to produce only 75 to 80% of that capacity in 2009. Suriname: At the end of April, Alcoa World Alumina and Billiton Suriname Holdings reached an agreement in principle where Suriname Aluminum (Suralco), an Alcoa subsidiary,

will acquire the bauxite and alumina refining interests of BHP Billiton Maatschappij Suriname (BMS), a BHP subsidiary, in Suriname. Terms were not disclosed. Late in July, Alcoa World Alumina completed its transaction to acquire BHP Billiton’s bauxite and alumina refining interests. Suralco has mined bauxite and refined alumina in Suriname since 1984. BMS had a 45% interest and Suralco a 55% interest in the joint ventures. Prior to the establishment of the joint ventures, BMS had separately conducted mining operations in the country, while Suralco has been active in Suriname for almost 100 years. USA: In February 2009, Noranda Aluminum talked with its joint-venture partner to close the Gramercy Alumina refinery in Gramercy, La. Gramercy Alumina is a 50:50 partnership between Franklin/Tennessee-based Noranda and Century Aluminum, Monterey/California, and it has a nameplate alumina capacity of 1.2 m tpy, of which 80% is smeltergrade alumina. The production cost of alumina purchased from Gramercy exceeded the cost of alumina available from third-party sources, and Noranda was evaluating the possibility of curtailing all of Gramercy’s operations. Spot alumina prices had dropped to about USD170 per tonne f.o.b. from a peak of around USD430 per tonne in early July 2008. This was troubling for Gramercy, considering it has a higher cost of operation due to elevated labour costs and because all of its bauxite is shipped in from Jamaica. Gramercy is supplied by St. Ann Jamaica Bauxite Partners Ltd. Noranda was also in negotiation with Century concerning the future of Gramercy and St. Ann after 31 December 2010, when their current contract expires. Higher raw material costs, primarily due to Gramercy, had an USD8.9m unfavourable impact on Q4 2008 operating earnings compared with the corresponding period a year earlier. Because of the global downturn in aluminium demand, Gramercy was producing at approx. 50% of capacity. Gramercy is supplied by St. Ann Bauxite, a mining facility in Jamaica with a capacity of 4.8m tpy, which was

ALUMINIUM · 3/2010

economics

running at the end only at 40% of its capacity. In return for its equity in the mining and refining operations, Noranda agreed to release Century from certain obligations and pay Century approximately USD10m in cash. The deal closed by the end of August. As part of the deal, Century entered into an agreement to purchase alumina from Gramercy in 2009 and 2010. Century’s primary aluminium smelter in Hawesville/Kentucky currently receives all of its alumina supplies from Gramercy. Venezuela: In February 2009, the Los Pijiguaos bauxite mine owned by Venezuelan bauxite and aluminium producer Bauxilum designed to produce 6m tpy was operating at only 50% capacity due to a shortage of input supplies that prevented

machinery from functioning normally. Infrastructure for mining and processing Los Pijiguaos’ includes the mine, the crushing mill, a 4.5 km conveyor belt, a 52 km railroad and control centre. An operational breakdown at Bauxilum would cause the entire aluminium production chain to collapse. Bauxilum also operates a 2m tpy alumina plant in Guayana region’s Puerto Ordaz city. State heavy industry holding CVG controls 99% of Bauxilum and the remainder is held by Rio Tinto Alcan. In October, Bauxilum signed an agreement with state-owned development bank Bandes and the Chinese-Venezuelan joint fund to access 100m bolívares (USD46.5m) and USD39m for the company’s recovery. This money will be invested under worker supervision, and with this

urgent work the plant can start to recover. The fact that workers will now be given a say in where the funds will be spent is the most important part of the agreement. The lack of investments in technology upgrades in Bauxilum has drastically lowered the company’s production. In September, Bauxilum suspended part of its sales to international clients to favour local buyers. Bauxilum previously presented a recovery plan to the basic industries and mining ministry (Mibam) calling for an investment of nearly USD91m to save the company. The company has already reduced its production goal for this year from 1.7m to 1.4m tonnes of alumina due to technical and economic difficulties. To be continued in ALUMINIUM 4/2010

Dubal celebrates major production milestone

Dubal

Cast metal production at Jebel Ali-based smelter complex exceeds one million tonnes in 2009

Excellent reason for celebrating: Dubal’s Jebel Ali smelter produced a record of cast aluminium products in 2009

The Jebel Ali primary aluminium complex, owned and operated by Dubai Aluminium (Dubal), produced 1,009,772 tonnes of cast aluminium products in 2009. Ranked as the world’s largest modern smelter with a captive power station and widely regarded as the industrial flagship of the United Arab Emirates, the entirely state-owned enterprise attributes the achievement of this major production milestone to a strate-

ALUMINIUM · 3/2010

gic focus on optimising capacity utilisation, maximising operating efficiencies, continuous innovation and pro-actively meeting market needs. “Exceeding one million tonnes in finished products in a single year is a tremendous feat for Dubal – especially as an annual production volume of 1,009,772 tonnes makes Dubal the largest single-site aluminium producer of value-added products in the world,

by far”, said Abdulla Kalban, the company’s president and CEO. The record not only fulfilled a corporate objective in its 30th anniversary year, but it was also achieved in the midst of the global economic recession, which forced many other primary aluminium producers into a partial close-down of production capacity. Dubal has continued to operate at full capacity throughout the downturn “and, as in prior years, we presold our entire production”, Mr ➝

17

economics

Kalban said. “We did this by establishing new markets for our metal, changing our product mix to meet the needs of our customers, enhancing process efficiencies and improving our productivity levels” – a strategic combination that enabled a 6.5 percent year-on-year increase in cast metal production compared to the 947,751 tonnes cast in 2008. In general, Dubal manufactures aluminium products in three broad categories at Jebel Ali: foundry alloy for automotive applications, extrusion billet for construction, industrial and transportation purposes and also high purity aluminium for the electronics and aerospace industries. The product portfolio also includes bus bars for the primary aluminium industry (used in-house and sold to other smelter complexes). More than 112 different products are manufactured, the majority of which are customised to customer specifications. The 2009 production milestone, set by Dubal’s casting operations, marks the fruition of the successive expansion projects undertaken at the Jebel Ali site between 1990 and 2008. Dubal’s smelting capacity has grown from 135,000 tonnes per year since its start in 1979 to a current one million tonnes per annum, which is a sevenfold increase. “The capacity of our casting operations has expanded in parallel: from an initial 490 tonnes per annum it has grown 159.39 percent to a current 1,271,000 tonnes per annum — which makes it the largest in the world”, Mr Kalban said. Since inception, Dubal’s casting operations have repeatedly notched up world-class performance achievements. The first one million tonnes of finished products was produced in 1987, with the five millionth cumulative tonne production milestone being reached in 2001. Just six years later, in October 2007, Dubal manufactured the ten millionth cumulative tonne of finished products. In 2009 alone, several new records were set: • The order for 40,000 tonnes worth of anode/bus bars for the Emirates Aluminium (Emal) potlines was completed (execution of the order began in 2008) • A record of 29,891 tonnes of sow

18

ingots was produced – which annualised to 359,000 tonnes • The world record in billet casting (in terms of maximum number of casts per day) was achieved in April 2009, giving an annualised casting capability of approx. 735,000 tonnes. • A record of 14,816 tonnes was achieved in standard ingot production in November 2009, which gives an annualised figure of 221,000 tonnes. Ever-ambitious, Dubal has set its sights on an even higher cast metal production volume of 1,024,000 tonnes in 2010 which will mean utilising 80.6 percent of the casthouse production capacity (compared to 79.4% in 2009). Kalban added: “Our company has a proven track record over the past 30 years. Going forward, we are confident that our business model will continue to deliver further sustainable growth.” About Dubal Dubai Aluminium Company Ltd owns and operates the world’s largest modern primary aluminium smelter with a captive power station. Built on a 480hectare site in Jebel Ali, the complex’s major facilities comprise a one million tpy smelter, a 2,350 MW power station, a large carbon plant, casthouse operations, a 30 million gallon perday water desalination plant, laboratories, port and storage facilities. The Jebel Ali serves 300 customers in at least 45 countries, predominantly in the Far East, Europe, the Asean region, the Middle East and Mediterranean region, and North America. The company holds ISO 9001, ISO/TS 16949, ISO/IEC 27001, ISO/IEC 20000, ISO 14001 and OHSAS 18001 certification at its Jebel Ali site and has twice won the Du-

bai Quality Award in the Production and Manufacturing sector (1996 and 2000). More than 4,100 operators, tradesmen, administrative staff, technicians, professionals and managers are employed by Dubal. Some 24 percent of the total workforce is drawn from the local population, with UAE nationals holding over 70 percent of senior management positions. Dubal also holds a 50 percent share in Emirates Aluminium (Emal), a green-field smelter development at Al Taweelah, Abu Dhabi. Commissioning of the first phase of Emal (comprising a 756,000 tpy smelter plus associated power generation, reduction material and casting infrastructure) began in December 2009. Driven by a quest for continuous improvement and ongoing innovation, Dubal has invested substantial sums of money over the past 25 years in developing advanced reduction cell technologies that not only improve productivity but also reduce the operations’ impact on the environment through improved energy efficiency and minimised emission levels. This has culminated in Dubal’s proprietary DX technology – a flagship technology that operates at 370 kA plus and therefore ranks among the best in its class. Developed in 2006, DX technology has been implemented in a dedicated 40-cell potline at the Jebel Ali smelter complex and is being installed at Emal, which will ultimately produce 1.5 million tpy. Entirely state-owned, Dubal is one of the largest non-oil contributors to the economy of Dubai and is widely regarded as the industrial flagship of the UAE. Having begun to tap metal at the Jebel Ali site in November 1979, the company celebrated its 30th anniversary in 2009. ■

emal delivers to first local customer Emirates Aluminium (Emal) has won its first local customer Trans Gulf Aluminium (TGA), a manufacturer of aluminium wire rods and aluminium alloy ingots. “This marks the beginning of what we hope will be a long lasting relationship between our two companies. Emal is a cor-

nerstone in the UAE’s diversification strategy, but the role we play extends beyond the work we do here at the smelter. The aluminium we produce creates additional downstream opportunities for other diversification projects like TGA”, said Emal CEO Saeed Fadhel Al Mazrooei.

ALUMINIUM · 3/2010

WiRTscHAFT

Druckgussindustrie sieht chancen für zweistelliges Wachstum 2010 Anlässlich der Euroguss-Messe im Januar in Nürnberg gab Gerhard Eder, der Vorsitzende des Verbandes Deutscher Druckgießereien (VDD) eine Einschätzung der Marktsituation für die Druckgussindustrie. Nach den drastischen Einbrüchen der Branche im vergangenen Jahr – Aluminium verzeichnete dabei in den ersten neun Monaten 2009 ein Minus von 36,6 Prozent auf 235.400 Tonnen – erwartet Eder, dass die Fahrzeugindustrie in der zweiten Jahreshälfte wieder zulegt – zehn Prozent seien 2010 vorstellbar. Die Hersteller von Gießereimaschinen erwarten dagegen für dieses Jahr einen weiteren zweistelligen Umsatzrückgang. Eder machte aber zugleich deutlich, dass die Zuwachsraten der vergangenen Boomjahre auf absehbare Zeit vorbei sind. Dies hat mit der Wachstumsschwäche des Automobilsektors in Europa zu tun, dem mit fast 75 Prozent wichtigsten Absatzmarkt für Leichtmetalldruckguss. Die Marktzuwächse in China und Indien werden weitgehend in diesen Ländern selbst gedeckt; die großen Fahrzeughersteller haben in den prosperierenden Ländern in Fernost eigene Produktionen aufgebaut. Abwrackprämien

Die casting industry expects double-digit growth in 2010 At the Euroguss trade fair in January in Nuremberg, Gerhard Eder, chairman of the Association of German Pressure Die Casting Foundries (VDD), gave a status report on the market situation for the die casting sector. After a dramatic slump in 2009 – die castings from aluminium declined 36.6 percent to 235.400 tonnes in the first nine months of the year – Mr Eder is confident that the automotive industry will return to growth this year. Growth of castings could stabilise at about ten percent, he said. By contrast, the manufacturers of casting machinery and equipment expect another year of negative sales rates in double-digit dimension. Mr Eder emphasised that booming growth rates of the past years were history. The reason is obvious and lies in the automobile sector, with 75 percent the most important sales market for light metal die castings. The large market growth in regions like China and India will be covered largely within these countries. The big car manufacturers have set up

Die casting production by types of metal in Germany 1988 to 2008 (in tonnes)

20

their own production facilities in the prospering Far East countries, which hardly create job security or turnover in Germany or Europe. Scrapping bonuses or comparable schemes at European level have made the market even tighter. The market for mid- and top-range cars will hardly grow disproportionately high and the demand for commercial vehicles has slumped drastically. “These markets will stagnate and a ray of sunshine can hardly be detected here for 2010. However, I do hope that the automotive industry will start growing again in the second half of 2010”, Mr Eder said. He added: “From an optimistic viewpoint, our association assumes that the present growth of castings could stabilise at about ten percent in 2010 in the best case. The die casting foundries will no doubt need 2011 and possibly even 2012 to return to the level of 2006 and 2007.” According to Mr Eder, the situation is different for die casting foundries in some industries that are still flourishing, such as power systems, medical engineering and parts of the electrical industry. The declines there were only minor – if at all, because these industries need smaller batch sizes, which are just right for SME suppliers. Though the sector was hit hard by the crisis, it is worth stating that the production of die castings has grown continuously over the past years and decades. No other casting process has shown comparable dynamics. The die casting foundries as component suppliers to car manufacturers, machinery and plant manufacturers as well as other sectors of industry, such as communication technology, the furniture industry, and the electrical and electronics

ALUMINIUM · 3/2010

economics

ALUMINIUM · 3/2010

oder vergleichbare Programme auf europäischer Ebene, die vor allem das Segment der Kleinwagen unterstützten, haben den Markt in Europa enger gemacht. In der automobilen Mittel- und Oberklasse sind ebenfalls keine dynamischen Zuwächse zu erwarten und der Nutzfahrzeugbedarf ist drastisch eingebrochen. „Diese Märkte werden stagnieren, hier ist kaum ein Sonnenstrahl für 2010 zu erkennen. Ich hoffe aber, dass die Fahrzeugindustrie in der zweiten Hälfte 2010 wieder zulegt“, so Eder. Der Verbandsvorsitzende weiter: „Bei optimistischer Sichtweise geht unser Verband davon aus, dass sich der Gusszuwachs 2010 günstigstenfalls bei etwa zehn Prozent stabilisieren kann. Druckgießereien brauchen wohl das Jahr 2011, wenn nicht sogar 2012, um sich wieder auf dem Niveau von 2006 und 2007 einzufinden.“ Anders sehe die Situation für Druckgießereien aus, die in weiterhin florierende Industrien wie Energietechnik, Medizintechnik und partiell in die Elektroindustrie liefern. Hier seien, wenn überhaupt, nur sehr geringe Rückgänge zu verzeichnen. In diesen Industrien werden kleinere Losgrößen verlangt, genau richtig für kleine, mittelständische Anbieter. Zwar wurde die Branche von der Krise hart getroffen, doch darf nicht übersehen werden, dass die Druckgussindustrie langfristig kontinuierlich zugelegt hat. Kein anderes Gießverfahren kann eine vergleichbare Dynamik vorweisen. Die Druckgießereien haben nicht nur als Zulieferer der Automobilhersteller und des Maschinen- und Anlagenbaus, sondern

auch für andere Industriezweige wie Kommunikationstechnologie, Elektronikbranche und Möbelindustrie kontinuierlich an Bedeutung gewonnen. Im vergangenen Jahr beschäftigte die deutsche Druckgussindustrie immerhin rund 17.000 Mitarbeiter in 290 Betrieben. Und der Gesamtumsatz lag 2008 bei 2,5 Milliarden Euro. Doch nicht nur in Deutschland, auch in Europa und weltweit entwickelt sich die Gießereibranche, und dies meist bei deutlich günstigeren Rahmenbedingungen als in Deutschland. Eder verweist auf den Anteil der Personalkosten an den Gesamtkosten (ohne Metall) in deutschen Gießereibetrieben, der bei über 50 Prozent liege. Deutschland befindet sich damit im internationalen OECD-Vergleich weiterhin auf dem dritten Platz bei den Arbeitskosten. „Belastend wirken auch die kontinuierlich steigenden Energiekosten, die im Vergleich zu vielen anderen Produktionsstandorten im Ausland schlicht und ergreifend nicht mehr wettbewerbsfähig sind.“ Die Gießereiindustrie im Allgemeinen und die Druckgießereien im Speziellen sei eine energieintensive Branche. Deren Energieanteil an den Produktionskosten betrage sechs bis zehn Prozent, beziehe man die gesamte Wertschöpfungskette in die Betrachtung mit ein, etwa die Vorstufe der Metallerschmelzung, liege der Energiekostenanteil bei bis zu 30 Prozent. Auch die Kostenentwicklung der metallischen Vorstoffe für die Gießereiindustrie hat in den letzten Jahren an Bedeutung gewonnen. Die in den Druckgießereien einge- ➝

Sales of alloy die castings by customer groups   in Germany in 2008 – in percent

Grafiken: VDD

industries have continuously gained in importance. In 2008, the overall turnover was 2.5 billion euros. Mr Eder pointed out that in times of globalisation, it would be foolhardy not to expect that die castings could also be manufactured abroad and at distinctly more favourable terms than at German locations. Therefore, it is important to be better than the “cheap foreign competition”. The share of personnel costs in German firms is more than 50 percent of the total cost (without metal). In the OECD international comparison, Germany still holds third place in terms of labour cost. Another issue for the German industry are the continually rising costs of energy, which in comparison with many other production locations abroad are simply not competitive, according to Mr Eder. The development of costs for metal raw materials is another issue that has become increasingly relevant and controversial for the industry. The metals used in die casting foundries are usually made from recycled scrap metal. Due to the enormous need for raw materials of all kinds, especially in the Asian region, this constantly leads to tremendous leaps in the prices of raw materials for the die casting sector. “If the die casting foundries want to remain profitable, these increases must be passed on to the market, which is not always easy”, he said pointing to the car manufacturers as main customer group which present there own costcutting programmes aimed at purchasing ‘cost-optimised’ components – in other words, at lower prices. The most important application market for die cast products is, and remains, the automotive industry. That goes along with some risks, but the opportunities for the sector are greater, Mr Eder is convinced. His explanation: die castings are an essential part of modern and efficient cars, today and even more tomorrow. As die casting only pays off in large quantities, this process is especially interesting for component products in the automotive industry, such as engine blocks, chassis parts, steering and brake systems, gearbox components and housings as well as interior parts. The persistent pressure ➝

21

WiRTscHAFT

setzten Metalle werden in der Regel aus recyceltem Schrott hergestellt. Bedingt durch den enormen Bedarf an Rohstoffen aller Art, speziell im asiatischen Raum, führt dies immer wieder zu großen Preissprüngen bei den Vormaterialien der Branche. Diese müssen, wollen die Druckgießereien weiterhin rentabel bleiben, an den Markt weitergegeben werden, was nicht immer einfach ist. Eder verwies in diesem Zusammenhang auf die Automobilindustrie und den Preisdruck, den die OEMs auf die Zulieferer ausüben. Der wichtigste Zielmarkt für Druckgussprodukte ist und bleibt die Fahrzeugindustrie. Trotz der hohen Abhängigkeit von dieser Branche seien die Chancen hier deutlich größer als die Risiken. Druckgussteile sind ein wesentlicher Bestandteil moderner, leistungsfähiger Automobile. Da sich das Druckgussverfahren erst ab größeren Stückzahlen rechnet, ist es besonders für Zuliefererprodukte wie Motorblöcke, Fahrwerksteile, Lenkungs- und Bremsanlagen, Getriebegehäuse und Getriebeinnenteile sowie Interieurteile interessant. Der anhaltende Substitutionsdruck zugunsten von Leichtbauwerkstoffen bleibe ein wichtiger Wachstumsmotor der Aluminium- und Magnesiumgussproduktion, speziell im Druckgießverfahren. Vor diesem Hintergrund schätzt

Eder die mittelfristigen Aussichten für die Druckgießer positiv ein. „Wenn wir uns auf unsere Fähigkeiten besinnen, Innovationen vorantreiben und ingenieurmäßiges Denken wieder verstärkt in den Mittelpunkt unseres Handelns stellen, haben wir eine gute Chance, die Krise zu meistern“, sagte er. Durch die hohen Produktionsraten in den letzten Jahren habe die Branche sich mehr und mehr auf die Optimierung der Fertigungsabläufe konzentriert und die Gießzyklen verkürzt. Dabei sei die Weiterentwicklung des Gießprozesses möglicherweise etwas vernachlässigt worden. Zudem müsse sich wieder intensiver um die Werkstoffe gekümmert, das heißt auch Grundlagenforschung in diesem Bereich betrieben werden. europäische Hersteller von Gießereimaschinen erwarten weiteren Umsatzrückgang Gutmann Habig, Generalsekretär von Cemafon, betonte auf der Euroguss-Pressekonferenz, dass die Gießereimaschinenindustrie 2009 durch einen massiven Umsatzeinbruch gekennzeichnet war, der in Deutschland rund 40 Prozent betrug. Die Auftragseingänge waren sogar noch stärker rückläufig. Doch auch für diese Branche scheint das vierte Quartal 2009 den Tiefpunkt markiert zu haben. Seit Beginn dieses Jahres sei ein

World machinery trade – major export nations for die casting machinery 2007 / 2008*

22

on replacing parts in favour of lightweight materials remains a major driving force for the production of aluminium and magnesium castings, especially using the die casting process. Against this background Mr Eder is optimistic about the medium-term prospects for the sector. “If we turn to our skills, push innovation and focus on engineering thinking again, we have a good chance of coping with the crisis”, he said. Due to the high production rates in the past years, the firms had concentrated on optimising production flows and shortening casting cycles, and had possibly neglected improving the casting process as such. Moreover, the industry should pay more attention to its materials again, that is to carry out fundamental research in this field, he concluded. european manufacturers of die casting machinery expect further decline in sales Gutmann Habig, general secretary of Cemafon, the European Committee of the Manufacturers of Materials and Products for Foundries, said at the Euroguss press conference that the European foundry machinery industry in 2009 had been marked by a heavy plunge in sales (e. g. minus 40% in Germany) and an even larger drop in orders received. However, this industry too seems to have reached its trough in the fourth quarter of 2009. Since the beginning of this year a slight upward trend both in Europe and in the export business had been noticeable, he said. On the other hand, the sector does not expect a return to positive sales growth in 2010 but a “flattening of negative rates” and a possible decline in turnover of 20 percent. Cemafon embraces the respective national associations and thus all major manufacturers of foundry machinery and plant, furnaces and products for the foundry industry in Europe. It represents the economic and technical interests of its members worldwide, offers information on market and technical developments and creates a

ALUMINIUM · 3/2010

economics

platform for the exchange of views at European level. The representation of interests encompass, among others, the harmonisation of European safety standards under the Machinery Directive and the creation of ‘guidelines’ for specifying technical rules and agreements, for example on interface issues, die casting machinery and peripheral equipment. Cemafon represents about 160 European manufacturers of foundry machinery with a production volume of more than one billion euros. These companies account for almost 90% of the European industry’s production volume and hold a 40% share of total world exports. Moreover, Cemafon represents practically all well-known European die casting machinery manufacturers with a production volume of approx. 300 million euros. Their share of total world exports is 40% too. The Cemafon export structure shows increased shares for EU27 and America, but declines in Asia, especially in China. ■

leichter Aufwärtstrend in Europa und im Export spürbar. Allerdings: Eine Rückkehr zu positiven Umsatzzahlen sei auch 2010 nicht zu erwarten. Habig sprach von einer „Abflachung der Negativraten“ und einem möglichen Umsatzrückgang von 20 Prozent im laufenden Jahr. Cemafon ist das europäische Komitee der Hersteller von Gießereimaschinen und -ausrüstungen. Als Dachverband mit Sitz in Frankfurt umfasst es die jeweiligen nationalen Verbände und damit alle bedeutenden Hersteller von Gießereimaschinen und -anlagen, Öfen und Produkten für die Gießereibranche in Europa. Die Interessenvertretung erstreckt sich auf die wirtschaftlichen und technischen Belange der Mitgliedsunternehmen, die Aufbereitung von Marktinformationen und technischen Entwicklungen und den Erfahrungsaustausch auf europäischer Ebene. Wichtige Aspekte der Interessenvertretung betreffen die Harmonisierung europäischer Sicherheitsstandards

unter der Maschinenrichtlinie und die Erstellung von „Einheitsblättern“ zur Festlegung technischer Regeln bzw. Vereinbarungen, zum Beispiel zu Schnittstellenthemen, Druckgießmaschinen und Peripheriegeräten. Cemafon vertritt rund 160 europäische Gießereimaschinenhersteller mit einem Produktionsvolumen von mehr als einer Milliarde Euro. Diese Firmen erbringen fast 90 Prozent des europäischen Produktionsvolumens der Branche und halten einen Anteil von circa 40 Prozent am Gesamtweltexport. Darüber hinaus vertritt Cemafon praktisch alle namhaften europäischen Druckgießmaschinenhersteller mit einem Produktionsvolumen von rund 300 Millionen Euro. Ihr Anteil am Gesamtweltexport beträgt ebenfalls 40 Prozent. Die Cemafon-Exportstruktur weist Zuwächse der Anteile in den EU-27 und Amerika auf, in Asien und besonders in China dagegen Rückgänge.

■

Protecting the environment and cutting costs. TCF (Twin-Chamber Melting Furnace)-Recycling Plant: ■ melting of contaminated scrap ■ TCF-Process ■ metal circulation system ■ automatic charging equipment ■ integrated control system

Visit us! Booth 10A61 April 12-16

ALUMINIUM · 3/2010

Benefits: ■ easy pouring ■ very safe operation ■ fully automatic operation ■ environmental friendly ■ reliable operation

LOI Thermprocess GmbH - Am Lichtbogen 29 - 45141 Essen / Germany Phone +49 (0)201 1891.1 - Fax +49 (0)201 1891.321 [email protected] - www.loi-italimpianti.com

23

ALUMINIUMrecycLINgINDUSTrIe

VAR-Vorsitzender Oetinger zu Aluminiumschrottexporten nach China:

Für die deutsche Aluminiumrecyc­ lingindustrie war das vergangene Jahr ähnlich schwierig wie für die meisten anderen Branchen. Im Anschluss an die extrem ge­ ringe Produktion im ersten Quar­ tal 2009 sei die Auslastung der Schmelzwerkskapazitäten zwar gestiegen, habe aber im mehrjähri­ gen Vergleich weit unter „normal“ gelegen, so der Vorsitzende des Verbandes der Aluminiumrecyc­ lingindustrie (VAR), Erich Oetin­ ger, auf einer Pressekonferenz Mitte Januar. Inzwischen hat sich die Nachfrage auf niedrigem Ni­ veau stabilisiert.

Schrottseparierung in einem chinesischen Betrieb – Handarbeit dominiert, was die spätere Gussqualität gegenüber technisch unterstützter Sortierung beeinträchtigt

keine Rede sein, da unklar ist, wie sich der Auftragsbestand in den kommenden Monaten entwickeln wird“, erklärte Oetinger. Die Preise für Aluminiumlegierungen seien im Zuge der allgemeinen NE-Metallhausse stärker als zunächst erwartet gestiegen. Ob sich das erreichte Niveau jedoch behaupten kann, bleibe abzuwarten. Oetinger verwies darauf, dass die Londoner Metallbörse LME, deren Aluminiumnotierungen bis zu einem gewissen Grad als Preisreferenz dienen, derzeit stark von institutionellen Anlegern beeinflusst werde, sodass die LME-

Grafiken: VAR / OEA

Vorläufige VAR-Zahlen für Deutschland lassen für das vergangene Jahr einen Produktionsrückgang bei Aluminiumgusslegierungen von mehr als 20 Prozent im Vergleich zu 2008 erwarten. Gezielte und aufgrund von Insolvenzen erzwungene Produktionskürzungen haben den übrigen Schmelzwerken zeitweilig ein wenig Luft verschafft. Aktuell, das heißt zu Anfang 2010, hat sich die Nachfrage auf dem erreichten Niveau stabilisiert. „Auffallend ist allerdings, dass vergleichsweise kurzfristig geordert wird. Von einer wirklichen Entspannung der Lage kann bisher aber noch

G. Kirchner

„Klimatische entwicklungshilfe gefährdet Versorgung in europa“

24

Notierungen die fundamentale Marktsituation nur bedingt reflektieren. Die Ertragslage der Schmelzhütten hängt bekanntlich von der Spanne zwischen Rohstoffkosten und Verkaufspreis ab. Diese Differenz umfasst die Produktions- und Kapitalkosten sowie den Ertrag. Der Rohstoffkostenanteil am Verkaufspreis liegt bei rund 80 Prozent. Zur Geschäftslage verwies der VAR-Vorsitzende darauf, dass die Gusslegierungsproduktion zu rund vier Fünfteln in den Automobilsektor geht und die Aluminiumschmelzhütten damit sehr stark von der Entwicklung dieser Branche abhängen. Mit dem Auslaufen der Abwrackprämie in Deutschland sind die Verkäufe von Kleinwagen deutlich gesunken; der Verkauf von Fahrzeugen der Mittelund Oberklasse im In-und Ausland weist dagegen eine leicht steigende Tendenz auf. Durch das Recycling werden inzwischen 35 bis 40 Prozent des Aluminiumbedarfs in Europa gedeckt. Zahlen und Fakten 2008 2009 Gusslegierungen 658.084 t 513.807 t Desox­Aluminium 62.814 t 51.844 t Gesamt 720.898 t 565.652 t Tab. 1: Gesamtdeutsche Produktion von insgesamt 14 Unternehmen mit 21 Aluminiumschmelzhütten

ALUMINIUM · 3/2010

in % -21,9 -17,5 -21,5

S AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e A LPU e M IcN II U Recyceltes Aluminium wird in Form von Guss- und Knetlegierungen hergestellt. Qualitativ gibt es keinen Unterschied zwischen Legierungen, die aus Primärmetall und solchen, die aus recyceltem Aluminium hergestellt sind. Dass trotzdem von Primär- und Sekundärlegierungen gesprochen wird, liegt darin begründet, dass bestimmte Legierungseigenschaften spezielles Vormaterial benötigen. Hier ist es dann sinnvoll, Primärmetall zur Legierungsherstellung zu verwenden. Nettoschrottexporte weiten sich aus Mit Blick auf die Rohstoffversorgung in Deutschland und Europa, wo es kaum oder nur geringe natürliche Rohstoffvorkommen für Aluminium gibt, hob Günter Kirchner, geschäftsführendes Vorstandsmitglied des VAR und Generalsekretär der OEA (Organisation of European Aluminium Refiners and Remelters) die wachsende Bedeutung des Aluminiumrecyclings hervor, auch vor dem Hintergrund „knapper, vor allem aber teurer

Energie“. Er verwies zudem auf die positiven Umwelt- und Klimaschutzeffekte des Aluminiumrecyclings. Rohstoffsicherheit und Klimaschutz seien daher „gute Gründe für den Gesetzgeber, richtige Rahmenbedingungen für den Fortbestand dieser Industrie in Deutschland und Europa zu schaffen. Hierzu gehören vor allem

die Beseitigung der umweltbedingten Wettbewerbsverzerrungen und der zahlreichen Handelsbarrieren.“ Kritisch sehen beide VAR-Sprecher, dass Jahr für Jahr mehrere Hunderttausend Tonnen Aluminiumschrott Europa in Richtung China und Indien verlassen. Die Versorgungsstrategie beider Länder schließt ➝

Gutachten im Auftrag der Scholz Aluminium GmbH

cO2-emission der Sekundärroute beträgt nur vier Prozent der Primärroute In einer Zeit steigender Energiekosten kann recyceltes Aluminium seine größte Stärke ausspielen. Schließlich werden zur Herstellung hochwertiger Aluminiumlegie­ rungen aus Aluminiumschrott bis zu 95 Prozent weniger Energie benötigt als zur Primärmetallerzeugung. Damit lässt sich die gesamte Energiebilanz des Werkstoffs Aluminium spürbar verbessern. Auch ein Blick auf die CO2­Bilanz von Recycling­ aluminium lohnt sich. Bedingt durch den niedrigeren Energieeinsatz ist die CO2­ Emission deutlich niedriger. Holger Ellmann, Geschäftsführer der Scholz Aluminium GmbH, stellte auf der VAR­Pressekonferenz eine vergleichende Bewertung der Primäraluminium­Metal­ lurgie mit der Produktion von Sekundär­ aluminium am Standort Deutschland vor, die vom Ingenieurbüro SHN durchgeführt wurde. Die Studie zeigt auf, dass die Sekundärroute nur etwa vier Prozent der Kohlendioxidemissionen im Vergleich zur

ALUMINIUM · 3/2010

Primärroute verursacht. Die Berechnung der CO2­Bilanz für die Scholz­Tochter Alustockach GmbH wurde Ende 2009 mit den Verbrauchszahlen für 2008 durch­ geführt und ist somit hochaktuell. Für die Betrachtung der Primärmetallurgie wurden Vergleichswerte herangezogen, die den Stoffeingang der Tonerde bis hin zum endgültigen Produkt einer deutschen Aluminiumhütte in den Blick nehmen. Logistik und Erzgewinnung wurden nicht betrachtet. Für die Pro­ duktion in der Sekundärroute wurde die Lagerung der Schrotte, die Aufbereitung, das Zusammenstellen der Chargen, das Schmelzen, die Auslieferung der Blöcke und Barren bzw. des Flüssigaluminiums herangezogen. Basisdaten des durchgeführten Vergleichs sind eine OEA­Studie, wo­ nach der Primärenergiebedarf für die Gewinnung von Aluminium aus Tonerde 93,7 Gigajoule pro Tonne Aluminium

(GJ/t Al) beträgt; die Gewinnung aus Schrotten geht dagegen mit lediglich 6,4 GJ/t Al einher. Die CO2­Intensität für die Primärroute liegt nach Angaben der OEA bei 10,9 t CO2/t Al für Deutschland, in Gesamteuropa beträt sie wegen eines günstigeren Energiemixes dagegen nur 6,2 t CO2/t Al (mehr Strom aus Wasser­ kraft in Norwegen und Kernenergie in Frankreich). Die CO2­Emisssionen für die Sekundärroute liegen nach Berechnungen des Ingenieurbüros bei 0,4 t CO2/t Al für die Alustockach GmbH und den Energie­ mix in Deutschland. Diese Ergebnisse, so Ellmann, stützen die politische Forderung nach Befreiung der Sekundärhütten vom Emissions­ handel in der dritten Handelsperiode (Befreiung von den indirekten Kosten des Klimaschutzes bzw. der CO2­Anteile beim Strompreis) sowie nach einer Gleichbe­ handlung mit den Primärhütten bei der Subventionierung der Strompreise.

25

ALUMINIUMrecycLINgINDUSTrIe

den Aufbau einer eigenen Recyclingindustrie ein. Da das Aufkommen an Aluminiumschrott aber noch gering ist, wird dem Import hohe Priorität eingeräumt, begleitet von einer Abschottung der heimischen Märkte und einem vielfältigen Förderpaket zur Einfuhr von Metallschrotten. Vor diesem Hintergrund lag der Nettoschrottexport der EU15 im vergangenen Jahr bei rund 830.000 Tonnen. Allein nach China wurden 550.000 Tonnen verschifft, mehr als doppelt so viel wie 2008. Zwar kann zurzeit noch genügend Aluminiumschrott in der EU generiert werden, um die heimischen Schmelzhütten zu versorgen. Angesichts des ungebremsten Schrottbedarfs Chinas

und in zunehmendem Maße Indiens drohe jedoch irgendwann in Europa der Ausverkauf, wenn nicht frühzeitig gegengesteuert wird. „Man könnte sich über diese Form der klimatischen Entwicklungshilfe freuen, wenn nicht gleichzeitig hierdurch die Gefahr der Unterversorgung in Europa steigen würde“, so Oetinger. Seit dem Jahr 2002 ist die EU in wachsendem Maße Nettoimporteur von Aluminiumschrott. Temporär ist es hierdurch bereits zu Versorgungsengpässen gekommen. Da der globale Metallschrotthandel auf Basis des USDollars abgewickelt wird, stellt der Euro-Wechselkurs zumindest in den Euroländern noch eine gewisse Barriere gegen den übermäßigen Schrott-

abfluss dar. Da die natürlichen Rohstoffvorkommen in der EU sehr gering sind – die Bauxitgewinnung lag 2008 bei 2,8 Mio. Tonnen (weltweit 216 Mio. t) – ist Aluminiumschrott mit einem Gesamtaufkommen von knapp 5 Mio. Tonnen die wichtigste in der EU direkt verfügbare und sichere Rohstoffquelle. Positiv hob Kirchner hervor, dass die Politik zunehmend die Bedeutung einer eigenständigen Rohstoffpolitik für Europa entdecke, so dass auch von politischer Seite mit mehr Unterstützung bei der Sicherung heimischer Rohstoffe, zu denen auch Schrotte zu zählen sind, gerechnet werden kann. „Wir setzen hier einige Hoffnung auf die von der EU-Kommission auf den Weg gebrachte Raw Material Initiative“, sagte Kirchner. Diese Initiative anerkennt die Bedeutung einer Politik der Rohstoffsicherung für Europa in einem globalisierten Wettbewerb um Ressourcen. Mit diesem Ansatz wird auch die Bedeutung eines „Level Playing Field“, das heißt eines internationalen Wettbewerbs unter gleichen Rahmenbedingungen für europäische Unternehmen stärker als in der Vergangenheit von Brüssel anerkannt. Unklar ist jedoch noch, wie sich diese grundsätzliche Neuorientierung in konkrete Maßnahmen niederschlagen wird. Mit Blick auf den CO2-Emissionshandel in der dritten Handelsperiode ab 2013 hat Brüssel die Forderung der Branche, Sekundäraluminium aus Umwelt- und Klimaschutzgründen aus dem Emissionshandel komplett herauszunehmen, schon vor einiger Zeit abgelehnt. Schmelzwerke werden damit wie normale Industriebetriebe eingestuft und ab 2013 dem Emissionshandel unterworfen. Ein Ausweg für die Branche könnte die Ausnahmeregelung unter dem Stichwort „Carbon Leakage“ sein, die dann Außenhandel

2008

Gusslegierungen Import Export Aluminiumschrott Import Export

2009

486.298 t 452.661 t -6,9 171.320 t 146.632 t -14,1 543.868 t 351.183 t -35,4 702.754 t 742.812 t +5,7

Tab. 2: Außenhandelsbilanz 2008 und 2009 sowie Veränderungen gegenüber dem Vorjahr

26

in %

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D UA SL TU rMI IeN I U M A LPU e M IcN II U

greift, wenn ein erhebliches Risiko zu Produktionsschließungen und damit verbunden zu einer Verlagerung von CO2-Emissionen in Länder mit weniger strikten Klimaschutzbestim-

recycLINg INDUSTry

mungen besteht. In welchem Umfang eine solche Ausnahmeregelung letztlich umgesetzt wird, dazu hat Brüssel aber noch keine abschließende Position bezogen. Der VAR fordert für

seine Branche vollständig kostenfreie Emissionsrechte. Entsprechendes gilt für die in der Diskussion befindliche CO2-Steuer für die emittierenden Unternehmen, die nicht vom Emissionshandelssystem erfasst werden. Hier fordert der VAR für den Fall der Einführung einer CO2-Steuer die vollständige Steuerbefreiung dieser Unternehmen. Darüber hinaus plädiert die Branche für die Beibehaltung des Einfuhrzolls von sechs Prozent auf Aluminiumlegierungen. Diesen Zoll zu reduzieren oder aufzuheben würde zu weiteren Wettbewerbsverzerrungen führen. Hierzu zählt der VAR das bestehende Ungleichgewicht beim Umweltschutz zwischen EU-Staaten und einigen Nicht-EU-Staaten sowie Handelsbarrieren wie Exportzölle für Aluminiumschrotte in einer Höhe, die Exportverboten gleichkommt; hier hat die Branche besonders Russland und die Ukraine im Blick. ■

Scrap exports to china threaten supplies in europe in the long term Market needs in Europe are now covered to an extent of 35 to 40 percent by the recycling of aluminium. But for Europe’s raw material supplies and for environmental and climate protection as well, aluminium recycling is becoming increasingly important. According to Günter Kirchner, General Secretary of the OEA (Organisation of European Aluminium Refiners and Remelters) these are good reasons for Brussels to set the correct framework conditions to ensure that this industry has a future in Europe. In midJanuary, speaking to a group of journalists he advocated the elimination, above all, of environment-related distortion of competition and of the numerous trade barriers that exist. Kirchner regards it as critical that year after year huge quantities of aluminium scrap leave Europe for China and India. Net scrap exports from the EU-15 last year amounted to some 830,000 tonnes of which 560,000 tonnes were shipped to China alone, more than twice as much as in 2008. It is true that at present enough aluminium scrap can still be generated in the EU to keep up supplies to the

ALUMINIUM · 3/2010

domestic smelters, but such unrestricted demand from China and to a growing extent India as well will sooner or later threaten to deplete what Europe has for sale, unless controls are established well in time. Since 2002 the EU has been increasingly a net importer of aluminium scrap. Some temporary supply problems have already arisen because of this. Since the global trading of scrap metals is based on the US dollar, the euro exchange rate still forms something of a barrier against excessive scrap outflow, at least in the countries of the eurozone. Granted that the availability of natural raw material resources in the EU is very limited – for example, in 2008 bauxite extraction was around 2.8 million tonnes compared with 216 million tonnes worldwide – aluminium scrap, with a total output of some five million tonnes, is the most directly available and secure raw material source in the EU. Kirchner regards it as positive that in Brussels the importance of a European raw materials policy is being recognised more and more, so greater support can

be expected from the political side for safeguarding domestic raw materials, including of course scrap. It is still far from clear, however, how this fundamental change of attitude will be reflected by concrete measures. As regards CO2 emission trading in the third trading period beginning in 2013, for environmental and climate protection reasons some time ago Brussels rejected the call to exempt the secondary aluminium sector completely from emissions trading. Thus, melting plants are classified as ordinary industrial operations and will be subject to emissions trading from 2013. The sector is hoping for a ‘Carbon Leakage’ exemption regulation which would come into force in the face of a considerable risk of production shutdowns and the associated relocation of CO2 emission-producing activities to countries with less strict climate protection provisions. Concerning the extent to which such an exemption regulation will ultimately be implemented, Brussels has not yet adopted any firm position. The aluminium recycling industry is calling for completely cost-exempt emission rights.

27

ALUMINIUM recycLINg INDUSTry

Secondary aluminium smelting activities in 2009 Rudolf P. Pawlek, Sierre The secondary aluminium busi­ ness has suffered many bank­ ruptcies in 2009. The primary industry’s failure to cut production to match demand exaggerates the market loss for recycling indus­ tries. Many companies have gone into bankruptcy through lower of sales volume and value. Banks have bankrupted many others by withdrawing their existing credit, even when they are still able to pay their costs and interest on loans. The recession has again hit European and North American firms particularly hard, due to their higher expenses for labour, fuel, and environmental protection. The AMerIcAS Canada: In January 2009, Agor aluminium smelting filed for court protection from creditors and looked for a buyer for its plant in Bécancour, Quebec. The high-technology mill of Montreal-based Alsa Services Canada Inc., Agor’s Canadian subsidiary, with its proprietary technology for handling salt cake, shut down temporarily in mid-December 2008. Awaiting renewed demand, no date has been specified for reopening. However, Alsa’s sophisticated Bécancour operation continues to recover recyclable substances from dross leftovers from aluminium smelting, and hopes to set up a similar US facility in Kentucky or an adjacent state. Agor processes salt cake to recover salt flux, used in aluminium furnaces and the source of eventual salt cake, as well as are aluminium, ammonium sulphate and a fine-grained mineral substance with aluminium oxide predominating. USA: General Aluminum Manufacturing Co. announced the closure of its Richmond/Virginia plant in March 2009. The duration of the idling is unknown, but the plant would reopen when conditions improve in the automotive sector. The plant operated in Richmond for 17 years. The company is owned by Park-Ohio Holdings Corp., Cleveland. It has six

28

manufacturing plants, mostly in Ohio and Indiana. It supplies General Motors and Chrysler. Aluminium wheel supplier Superior Industries International Inc. announced the closure of its manufacturing facility in Van Nuys/California, in an effort to further reduce costs and more closely align its capacity with sharply lower demand for light vehicles. The company has sufficient capacity at its remaining five plants in North America and at a joint venture in Hungary to accommodate current and expected production requirements. The move eliminates approx. 290 jobs, representing 9% of Superior’s total work force, and saves about USD16.5m in annualised labour costs. The plant closure will likely be complete by the end of June 2010. The net book value of manufacturing equipment and related fixed assets at the facility was about USD17.4m. Superior is one of the world’s largest suppliers of cast and forged aluminium wheels for the car industry, with nine facilities in the US, Mexico and Europe. KB Alloys Inc. completed a USD2m expansion of its Henderson/Kentucky plant. The equipment installations were primarily focused on an upgraded strontium pre-alloy metal production plant, bar casting centres and conforming equipment used to produce ingot, bar, rod and coiled rod products for the aluminium industry. The new plant produces primarily a range of aluminium-strontium alloys such as 5Sr, 10Sr and 15Sr in 9.5 mm diameter cut rod and coiled rod and 2.2 cm diameter Korrect Bar forms. KB Alloys manufactures aluminium grain refiners, hardeners, master alloys and custom-engineered materials at facilities in Henderson, Reading and Wenatchee. Automotive aluminium and magnesium die caster Contech LLC filed for Chapter 11 bankruptcy protection at the end of January 2009 due to unprecedented lows in the North American automotive industry. The restructuring will provide necessary relief from significant debt, and it

will involve selling certain non-core operations. Contech has belonged to Marathon Automotive Group. The company said it will not conduct an open auction for the assets but entertain other bids until the court approves the sale to Revstone. Contech’s casting unit has six facilities in the US. The proposed purchase price for the casting assets was USD14m, with Revstone assuming certain Contech liabilities. Revstone had no plans to close the casting plants, and the wages and benefits of currently employed workers were substantially comparable to what Contech pays. The company was also looking to divest UK subsidiary Contech Operating UK Ltd, which operates a plant in Welshpool, Wales. Contech UK is a stand-alone operation in terms of cash flow and is not a debtor in the US bankruptcy filing. However, in order to maximise the value of its estate, Contech is looking to sell its 100% share of Contech UK to Hicorp Ltd, a company registered in England and Wales formed by and comprised of the management of Contech UK. Hicorp has agreed to pay £2.75m (USD4.3m). The deal required court approval. In February 2009, Aleris International Inc., producer of aluminium rolled products, extrusions and recycling, filed for bankruptcy protection for its US operations. The operations in Europe, Asia, South America, Mexico and Canada were not included in the voluntary reorganisation filing under Chapter 11 of the US Bankruptcy Code. Aurora Acquisition Holdings Inc holds a 100% equity stake in Aleris. Aurora is completely owned by private equity group TPG. To fund its global operations during the restructuring, Aleris secured USD1.075bn of debtor-in-possession (DIP) financing. Subject to court approval, the DIP credit facilities include a new USD500m term loan and a USD575m revolving credit facility that replaces the company’s previous revolving credit facility. The credit facility will be used for normal operating and working capital require-

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D UA SL TU rMI IeN I U M A LPU e M IcN II U ments, including employee wages and benefits, supplier payments, and other operating expenses during the company’s reorganisation. Auto supplier Hayes Lemmerz International Inc. has filed for Chapter 11 bankruptcy protection, while another Tier 1 supplier, Visteon Corp., warned that it is on the verge of bankruptcy. Northville/Michigan-based Hayes, which manufactures steel and aluminium wheels for passenger cars and light trucks, commercial trucks and trailers, as well as powertrain components, listed total assets of USD1.34bn and total debt of USD1.4bn. The company has already secured DIP financing to continue operating under a pre-negotiated restructuring plan that involves no interruption in supply to its customers. The DIP lenders will make up to USD100m available in added liquidity. The Chapter 11 filings were precipitated by an unprecedented slowdown in industry demand and a tightening of credit markets. These filings will allow Hayes to reduce its debt and restructure its balance sheet. At the beginning of June, Worthington Industries Inc. has bought the assets of Piper Metal Forming Corp., a manufacturer of aluminium high-pressure cylinders, and two related businesses. Piper, with one manufacturing location in New Albany/Mississippi, also makes extruded steel and aluminium parts for use in the medical, automotive, defence and oil services markets, among other industries. Also included in the deal are US Respiratory Inc., which assembles and distributes Piper’s medical cylinder products, and Pacific Cylinders, which provides distribution services on the West Coast. Worthington did not say how much it paid, but Piper’s revenues were about USD30m in the most recent calendar year. J.L. French Automotive Castings Inc. filed for Chapter 11 protection on 13 July in response to US automotive production declines and to industrywide credit restrictions. The Sheboygan, Wisconsin-based aluminium automotive components manufacturer also plans to reduce its secured debt to USD65m from about USD280m. It

ALUMINIUM · 3/2010

recycLINg INDUSTry

will do this through debt-for-equity swaps with first- and second-lien term loan lenders in an effort to provide a stable financial foundation for its operations. J.L. French and its domestic affiliates will complete a pre-negotiated restructuring under its Chapter 11 filing in the US Bankruptcy Court for the District of Delaware. None of the company’s foreign operations are included. J.L. French already has a USD15m DIP facility to fund working capital needs that might arise during the reorganisation. It expects to emerge from Chapter 11 within 90 days. At the end of July, Aleris International Inc. recalled more than 100 aluminium workers at its specification alloy and recycling plants in Coldwater and Saginaw/Michigan,

Steele/Alabama and Morgantown/ Kentucky. The ingot casting section of the sheet mill in Lewisport/Kentucky recalled for 25 people, partly due to increased activity and partly to replace retirees. Aleris is reorganising under Chapter 11 court protection. Aleris agreed to spend USD4.2m at 15 aluminium plants to reduce air emissions, according to the terms of an agreement with the federal Environmental Protection Agency (EPA). The settlement also included a USD4.6m civil penalty, although the EPA accepted the status of unsecured creditor in the Chapter 11 bankruptcy case covering Aleris’ U.S. operations. Negotiations had been ongoing for so long that the deal did not include two plants that Aleris purchased in 2007 from Wabash Alloys LLC. The ➝

Millmate Thickness Gauge. Reliable day and night.

With more than 100 installations worldwide the MTG has shown its reliability and exceeded our customers’ expectations. The green PEC measurement technology is environmentally-friendly, providing personal safety and totally eliminating the hazardous drawbacks of systems based on isotope or X-ray sources. MTG works impeccably in the toughest of environments and there is no need for calibration and alloy compensation inherent in older technologies. MTG is more than a thickness gauge and has several extra features including reliable clad measurement and a unique on-line measurement of electrical resistivity. www.abb.com/pressductor

ABB AB Force Measurement Phone: +46 21 32 50 00 Fax: +46 21 34 00 05

ALUMINIUM recycLINg INDUSTry

EPA examined one Aleris plant and cited problems, but the company suggested to the EPA that a settlement be negotiated that would involve all of the company’s facilities, whether or not they had violations or had been scheduled for inspection. Sapa announced the closure of its Morris/Illinois aluminium extrusion plant by November. The plant has not been profitable for several quarters and is now redundant due to Sapa’s recent USD151m purchase of bankrupt aluminium extruder Indalex Holdings Finance Inc. The

direct available UBCs to the lowestfreight-cost recycling facility. That leaves it to the joint venture whether a particular scrap purchase will go to a Novelis location or one belonging to Alcoa. At the beginning of September, Metal Exchange Corp. (MEC) acquired the assets of bankrupt aluminium disk manufacturer Element Aluminum LLC, positioning the diversified nonferrous metals company to expand its domestic fabrication capabilities. St. Louis-based MEC, a supplier, processor, purchaser and

for ¥4.5 billion (USD50m) in sales in 2014. In July 2008, Daiki and a Guangdong firm launched a joint venture to make secondary aluminium alloy. Half of the entity’s output is sold to Japan by Daiki, with the remainder sold in China by the local partner. But Daiki has decided it will also conduct its own Chinese sales operations, while at the same time boosting the venture’s capacity to around 100,000 tpy. Daiki’s offtake will be around 60,000 to 70,000 tonnes, of which it aims to sell about 50 to 60% to the Chinese market, with the rest exported to Japan and other regional markets such as Southeast Asia.

ALUMINIUM

eUrOPe

The new recycling furnace at Alunorf in Germany

operation’s casthouse produces 220, 254 and 440 mm diameter aluminium logs in six different alloys. Its two extrusion presses have the capacity to produce 91 tpd of aluminium profiles. The plant’s customers include automotive, truck trailers and electronics companies as well as assorted OEMs and service centres. A new Novelis-Alcoa joint venture, Evermore Recycling LLC, was announced on 24 August. Atlantabased Novelis is 55% owner. Evermore, based in Nashville, will act as purchasing agent for scrap going to Novelis and to Alcoa rolling mills. Nashville is roughly midway between an Alcoa plant in Tennessee and a Kentucky mill of Novelis, which is part of India’s Hindalco Industries Ltd. Evermore began setting up purchases by October, but scrap shipments under the new setup will not be taken until January. Since one of the joint venture’s purposes is to improve efficiency, the company will

30

market maker for the nonferrous industry, purchased Element’s Jackson facility through its affiliate ElementAl Holdings LLC for USD1.43m in cash, plus a USD870,000 credit bid and a USD170,000 note. Element filed for Chapter 11 bankruptcy in July amid financial difficulties. Production at the Jackson facility was not disrupted during the bankruptcy or transition and will continue unchanged as MEC spends the next four to six months updating equipment and systems at the site, which employs some 30 people. ASIA In December 2009, Japan’s Daiki Aluminium Industry ramped up its secondary aluminium alloy output in China by 150% to supply Japanese automakers and other manufacturers in China. Japan’s largest secondary aluminium producer, Daiki Aluminium will also set up a new sales unit in China, from which it is aiming

The proportion of aluminium beverage cans recycled in Western Europe rose to 61.8% in 2007 from a yearearlier 57.7%. A similar calculation for the United States that year tallied 53.8%. The European improvement was spearheaded by Sweden, with a six-point gain from 85% to 91%. Sweden has a refundable deposit fee, collected when beverages are sold. Other gains of 4% or more raised Spain to 57% recycling rate, the UK to 52% and Italy to 53%. Sorting and recycling technologies, if they separate aluminium cans effectively, achieve payback promptly even in a difficult economy. Sweden’s gain to 91% catapulted that country into a tie for first place with Germany and Belgium. At the low end were Portugal (31%) and Greece (36%). Annual can consumption figures for Eastern Europe also showed growth. However, there are no statistics to provide annual snapshots of recycling rates in that part of the continent. France: French aluminium recycler Sobral, which recently took over Société Nationale de Revalorisation’s (SNR) plant in Premery, went into receivership in April. The company was hit by the demise of French foundry Rencast, which went into liquidation in March. Sobral bought SNR to supply Rencast, and after that its debt was so great the company had no choice but to stop. Sobral had been buying struggling operations in France over the past six to seven years, and until

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D UA SL TU rMI IeN I U M A LPU e M IcN II U now it has been successfully putting them back on track. It acquired SNR for €500,000 in October after SNR was liquidated in June 2008. Germany: In March, aluminium casting alloys producer Metallhüttenwerke Bruch filed for administration as conditions in the European alloy market deteriorate. The company was forced into administration late in February. Although in administration, Bruch continues to produce alloy. The company blamed its problems on the deterioration of the automotive industry, with a drop in orders of more than 30%. Asperg had intended to build a new plant at Marbach and close its Asperg smelter, but then abandoned this plan, overhauling Asperg over the last few years as part of a modernisation process instead. German die caster Metal Technologies Kitzingen (MTK) filed for preliminary insolvency at the end of April and an administrator was appointed to the company. MTK has capacity of 79,000 tpy of gray and ductile iron castings and aluminium alloys, according to a March 2008 company presentation. MTK, formerly known as Sachs Giesserei, was running at about 60 to 70% of capacity because of weak market conditions. There are no problems at the plant – it is still in operation. In June, Spanish recycler Befesa agreed to buy two insolvent German salt slag recycling companies, Aluminium-Salzschlacke Aufbereitungs GmbH and Alsa Süd GmbH, from Agor AG for €23.4m. The assets comprise three production plants in the German municipalities of Hannover, Lünen and Töging, with combined treatment capacity of 380,000 tpy of waste. Befesa has two plants for recycling salt slag, one in Valladolid, Spain, and the other in Wales, UK, with combined capacity of 230,000 tpy. Commerzbank provided the external financing for the deal, and Befesa has been advised by Lincoln International investment bank. In November, Hydro opened a new 50,000 tpy remelting facility at the Alunorf plant in Neuss. It is a twinchamber furnace. This brings Hydro’s total recycling capacity in Germany to

ALUMINIUM · 3/2010

recycLINg INDUSTry

150,000 tpy of high-quality aluminium, and helps to reduce carbon emissions. The third furnace within three years has been built as part of the new recycling centre at Alunorf, the world’s largest aluminium remelting and rolling facility, which is a 50/50 joint venture between Hydro and Novelis. The new €16.6m investment makes the Alunorf plant more versatile and viable, adding recycling to the portfolio of activities, which focus on sheet ingot casting for subsequent hot and cold rolling. The Hydro recycling facility saves energy also by burning lacquer, as attached to the scrap metal, and directly using the emerging gas to power the remelting process. The centre stands out with its numerous environmental features, such as a regenerative combustion system, most

modern cleaning of exhaust gas, the complete re-utilisation of process remains, and indoor scrap handling. Italy: At the end of June, Italian secondary aluminium producer Fonderie Riva suspended output until the end of the summer due to poor market conditions. Low volume orders and high raw material prices prompted the company to take this decision. The company produces both secondary and primary ingot for casting. It has total capacity of 25,000 tpy. Latvia: Latvian aluminium alloy producer Dilers opened its new 16,000 tpy plant early in May and plans to capitalise on new contracts it has picked up since the market downturn. Dilers is confident that its new plant will be successful despite producers closing down elsewhere, having kept its ➝

WWW.BUSSCORP.COM

The leading Mixing Technology for Anode Pastes For over 50 years BUSS KE and CP series Kneaders have been the benchmark for reliable, cost-effective compounding of anode pastes. Now we go one step further.

ALUMINIUM recycLINg INDUSTry

production levels at 100% throughout the economic decline. The new plant produced two loads of material since its inauguration, while some fine tuning takes place. About 35 people will be employed at the facility once it is in full production. Dilers will continue to produce its current grades of aluminium ingot, such as DIN226, 231, 230 and 239, but will also be able to supply 500 to 700 tpm of liquid aluminium. The new plant includes three new reverberatory furnaces and cost about USD6.6m to build. Construction began in July 2008, four months later than expected because of administrative delays. Spain: In June, Spanish aluminium recycler Aluminsa-Aluminio Sala, which filed for Spain’s version of Chapter 11 debt protection in March, reported it is seeing the benefits of measures it has taken to improve its efficiency and cut costs. The restructuring is already having a positive effect on the company’s balance sheet. Aluminsa continues to operate at about 75% of capacity. UK: In January 2009, aluminium recycler RecovCo-Affimet went into administration because of difficult market conditions. The plant in Compiègne, France, has suffered from poor demand, in particular from the automotive industry. RecovCo-Affimet was Europe’s largest aluminium recycling company, producing 70,000 tpy of material. Under Alcan, it produced 90,000 tpy. Its capacity was increased from 55,000 tpy in January 2008 after a second tilting furnace was installed at the plant. UK aluminium ingot producer MilVer Metals halted production for the first week of February to reflect a lull in demand. In May, W Howarth Metals mothballed the furnace at its new foundry and will not reopen it until the economic climate improves. The company, which was bought by One51 in February 2008, had already stopped aluminium alloy production at its current operations in preparation for the move to a new three-acre site in June. Its new premises in Ardwick, Manchester, will open as planned and the company will continue its scrap metal trading business from there.

32

But the new furnace, in which the company has invested substantially, will not be commissioned until the market improves. W Howarth Metals employs about 35 people. According to the company, its former furnaces could melt, refine and cast 8,000 tpy of scrap aluminium. It produced silicon aluminium ingot, and was able to produce more than 50 specified international alloys. At the beginning of June, automotive aluminium die caster Contech Operating UK, a subsidiary of bankrupt Contech LLC, has been bought out for an undisclosed sum by a management team, headed by incumbent managing director Peter Radcliffe. The other management members involved in the buyout were Keith Brown, Mark Simpson and Carl Kitley. Contech is a primary supplier of high pressure and squeeze cast components, both machined and in the raw state, and it buys about 500 tpm of material. In September, Contech Operating UK changed its name to Castalum following the management buyout. The company is moving into a new product range and machining under a planned investment programme. Leeds-based aluminium die caster Thomas Brothers closed in October as a result of falling demand for its products and a loss of customers. The gravity die casting company specialises in the manufacture of high-quality aluminium castings for general and automotive industries, and has over 35 years experience in the industry. The company employs about 27 people. Demand for secondary aluminium die castings has fallen because of declining business from key consumers in the worldwide automotive industry. In November, Evans & Reid Alloys contemplated expansion by bringing a third party into the company. The Wolverhampton-based company produces between 4,800 and 6,000 tpy of high-grade secondary- and primarybased aluminium alloys including LM6, LM25 and L99. conclusions As in previous recessions, the secondary aluminium industry has suffered

even more in volume, in price and in liquidity than the primary industry. The primary smelters are very expensive to start and stop, and they are capital intensive. This means they tend to continue to sell metal at below cost price for some time, delaying amortisation and dividends. This surplus primary metal exaggerates the loss of sales volume and value for secondary smelters, which have a higher proportion of variable costs that they must continue to pay: labour, fuel, environmental protection expenses and interest on loans. Even when secondary businesses are still able to pay these costs, banks have pushed many of them into bankruptcy by withdrawing existing credit arrangements. This seems again unfair, in view of the very low interest rates at which governments now lend to banks to support businesses, and at which the banks lend to speculators in dormant primary aluminium ingot. These problems raise questions on financial market structure as well as on global environmental emissions rules and expenses. International government action is needed mitigate these problems. The London Metal Exchange needs rules to link metal price to stock levels before stock gets so far out of balance. Industry needs better access to financial credit. Environmental standards should be more equal between countries around the globe. Further consolidation in the secondary aluminium industry is the only way to ensure its survival in Europe and North America. The closures and idled capacity seen so far are not enough to ensure the industry survives. Secondary aluminium consumption fell by up to 40% in the first half of 2009 compared with 2007 levels. But overcapacity continues to restrict its recovery. It is predicted that in ten years there will be about ten secondary aluminium-producing companies in Europe. Moreover it is estimated there would be only one major company per country in Europe by 2019. There will be various cycles of consolidation and, ultimately, a higher diversification in recycled production.

■

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e A LPU e M IcN II U Interview mit Thomas Reuther, Vorstandsmitglied der Trimet Aluminium AG

„Wir bieten die klassischen Stärken des Mittelstandes: kurze entscheidungswege, eine gesunde Finanzstruktur, ein marktnahes Management“ Die Trimet Aluminium AG in Essen ist nicht nur der größte Produzent von Hüttenmetall in Deutschland, sondern betreibt auch ein umfassendes Recycling, das sowohl marktorientiert ist als auch die Versorgung der ei­ genen Automotive­Gießereien in Ostdeutschland sicherstellt. Die Redaktion ALUMINIUM sprach mit Thomas Reuther, verantwort­ licher Vorstand für die Bereiche Recycling und Automotive, über die allgemeine Marktsituation für die Umschmelzbetriebe und über das Recyclinggeschäft der Trimet in Verbindung mit den eigenen Gießereiaktivitäten.

Fotos: Trimet

Drehtrommelofen in Gelsenkirchen

Thomas Reuther

ALUMINIUM: Herr Reuther, die Krise in der Automobilindustrie hat die Recyclingbetriebe im vergangenen Jahr arg in Mitleidenschaft gezogen. Wie schätzen Sie die aktuelle Lage ein? Reuther: Der Markt der Umschmelzlegierungen ist derzeit durch eine deutlich gestiegene Nachfrage insbe-

ALUMINIUM · 3/2010

sondere bei den Abnehmern aus der Automobilindustrie gekennzeichnet. Die Schrottpreise sind wegen des strengen Winters stark nach oben geschnellt und außerdem treten Indien und China wieder stärker am Markt auf. Auf der Produktionsseite sind eine Reihe von Kapazitäten in Deutschland und Europa entweder vorübergehend stillgelegt worden oder ganz vom Markt verschwunden. ALUMINIUM: Um welche Größenordnung handelt es sich dabei? Reuther: Ich schätze, dass die Recyclingkapazität von rund 800.000 Tonnen in Deutschland um ein gutes Viertel gesunken ist. ALUMINIUM: Wird diese Entwicklung die Ertragssituation der Umschmelzer verbessern? Reuther: An der Margensituation hat sich bisher nichts geändert. Man partizipiert nicht an höheren Legierungspreisen, hat aber höhere Finanzierungskosten beim Einkauf. Das ist ein Problem, denn wenn die europäischen und deutschen Umschmelzer aufgrund ihrer wirtschaftlichen Situation nicht in der Lage sind, die Schrottpreise zu finanzieren, fließt das Material schnell an Dritte. ALUMINIUM: Sie sprechen damit die viel zitierte Finanzierungsklemme der Unternehmen an. Wie gravierend ist denn das Problem? Reuther: Die Finanzierung des Umlaufvermögens, sprich der Schrottund Fertigwarenbestände, ist für viele mittelständische Unternehmen

deutlich schwieriger geworden, da sie nicht über ausreichend Liquidität bzw. Finanzierungslinien verfügen. Dazu gibt es oftmals für diese Unternehmen keine ausreichende Kreditversicherung, was wiederum zu Aufschlägen bei den Schrottpreisen im Einkauf führen kann. Hinzu kommt, dass die Banken bei der Festlegung von Konditionen heute vielfach Branchen katalogisieren und weniger in die Einzelbetrachtung von Unternehmen gehen. Als Umschmelzer für die Automobilindustrie hat man es bei den Banken eher schwer. ALUMINIUM: Wie stellt sich die Lage für Trimet dar, die ja nicht nur Hüttenproduzent, sondern auch Umschmelzer und Autozulieferer ist? Reuther: Unsere Situation unterscheidet sich grundlegend von der des Wettbewerbs. Wir haben den Handel, das Umschmelzen, die Hütten und in der Verarbeitung das Automotivegeschäft. Den größten Teil unserer Schrotte beziehen wir von unseren Kunden, zum Beispiel von Druckgießereien und Weiterverarbeitern, bei denen große Mengen Späne anfallen. Wir streben vor allem langfristige Verträge mit den Kunden an. Dem kommt entgegen, dass die klassischen Verarbeiter den Schrott als durchlaufenden Posten und kalkulierbare Größe behandeln wollen. Da kann man auf LME-Basis dann mit Abschlägen und Prämien die Schrotte kaufen. Bei dem Großteil des Materials, das wir kaufen, handelt es ➝

33

ALUMINIUMrecycLINgINDUSTrIe

sich um sortenreine Neuschrotte. Der kleinere Teil sind Altschrotte, die in der Regel über den Handel bezogen werden, dies ebenfalls im Rahmen vor allem langfristiger Verträge. ALUMINIUM: Kaufen Sie die Schrotte zielgerichtet mit Blick auf ihre Gießereien Harzgerode und Sömmerda ein? Reuther: Das Recyclinggeschäft bei Trimet ist nicht primär auf das eigene Automotive-Geschäft in unseren Gießereien ausgerichtet, sondern marktorientiert. Der Vorteil bei Trimet ist, dass wir vom Handel bis zum Recycling alles bedienen können. Wir nehmen zum Beispiel von Automobilisten Sekundärschrotte zurück und liefern im Gegenzug Primärlegierungen. Das ist nur eine Frage des Tauschpreises. Für Schrott gibt es immer einen Markt, die Aufgabe des Händlers ist es, den jeweils passenden Markt zu finden. Dabei konzentrieren wir uns auf Deutschland und Europa. Wir agieren hier kundennah, zumal viele unserer Kunden diese Schrotte brauchen, um ihre Produktion aufrechtzuerhalten. ALUMINIUM: Das Recycling ist also ein eigenständiges Standbein unabhängig vom Gießereigeschäft? Reuther: Im Grunde sind wir hier strukturiert wie jeder Großkonzern – mit Geschäftsfeldern, die ergebnisverantwortlich sind. Natürlich hat die Versorgung unserer Automotive- und Formate-Gießereien hohe Priorität. Am Hüttenstandort in Essen werden wir Ende des ersten Quartals wieder alle Elektrolysen in Betrieb genommen haben, das sind aufs Jahr gerechnet 160.000 Tonnen Primärproduktion. Dem stehen 230.000 Tonnen Gießereikapazität gegenüber. Das Delta von 70.000 Tonnen decken wir über Kaltmetall, etwa zwei Drittel davon aus Schrotten, weil das so hergestellte Metall kostengünstiger ist. Aber wenn wir über Recycling bei Trimet reden, sprechen wir über ein Schrottvolumen zwischen 150.000 und 170.000 Tonnen, das wir in der eigenen Gruppe recyceln. Darüber hinaus handeln wir in der Größenordnung von 80.000 bis 100.000 Tonnen Aluminiumschrotten. Hier ergänzen sich unsere Produktion und unser Handelsgeschäft.

34

Kontrolle von Gussteilen in Harzgerode

ALUMINIUM: Die 170.000 Tonnen werden in Essen, Gelsenkirchen und Harzgerode eingeschmolzen? Reuther: Wir haben an den Standorten in Gelsenkirchen und Harzgerode gut 100.000 Tonnen Metallbedarf, die eingeschmolzen werden, hinzu kommen jene Mengen Schrott, die in die Hüttengießerei in Essen in den Prozess fließen. Wir produzieren schon heute rund ein Drittel des Metalls in Essen aus Schrotten. Ein standortnahes Recycling hat für uns eine hohe Bedeutung. Gerade mit Blick auf das Automotivegeschäft. ALUMINIUM: Können Sie das näher erläutern? Reuther: Denken Sie an die CO2-Diskussion, die für Hüttenbetriebe wie für die Automobilhersteller virulent ist. Mit einem standortbezogenen Recycling können wir unsere Energiebilanz auf sehr wirtschaftliche Weise verbessern. Das angesprochene Delta von 70.000 Tonnen Kaltmetall, um unsere Hüttengießerei in Essen auszulasten, können wir mit einem Bruchteil der Energie einschmelzen, die ein normales Umschmelzwerk benötigt. Das Metall aus der Elektrolyse geht mit über 900 Grad Celsius in die Gießerei. So heißes Material ist nicht vergießbar, und der Schmelzpunkt von Aluminium liegt bei 660 Grad Celsius. Wir geben die Schrotte daher als Kühlmetall zum flüssigen Primäraluminium hinzu. Wir setzen dabei sortenreine, blanke Produktionsschrotte wie Fensterprofile ein und mit zunehmendem Anteil auch Fahrwerksteile, weil diese Produkte

vor allem aus Primärmetall hergestellt werden. ALUMINIUM: Erfolgt der Einsatz von Primär- statt Sekundärlegierungen für diese Produkte aus Qualitätsgründen? Reuther: Das ist vor allem eine Frage der Legierungsentwicklung, die in der Vergangenheit nur von wenigen Umschmelzwerken vorangetrieben wurde. Für Sicherheitsteile im Automobil werden vorwiegend Hüttenlegierungen eingesetzt, weil es oftmals keine vergleichbaren Umschmelzlegierungen gibt. Unsere F&E arbeitet daran, Umschmelzlegierungen zu entwickeln, die die identischen Sicherheitsanforderungen erfüllen und dabei gleichzeitig Kostenvorteile mit sich bringen. Unser Ziel ist es, uns über die F&E-Expertise als Entwicklungspartner zu positionieren. Wir haben alle Prüfmöglichkeiten und mit Essen und Harzgerode zwei hervorragend ausgebaute F&E-Standorte inklusive einer Versuchsgießerei in Essen. Und wir haben grundsätzlich auch die finanziellen Mittel, um uns an Entwicklungsprojekten zu beteiligen. Wir bekommen so auch einen Ansatz, unser Metall in Projekte liefern zu können, wenn sie serienreif werden. ALUMINIUM: Wie erfolgreich sind Sie bei der Entwicklung von Umschmelzlegierungen als Substitut für Primärmetall? Reuther: Für einen OEM, der in der Formel 1 aktiv ist, produzieren wir, wenngleich nur in sehr kleinen Mengen, eine hoch anspruchsvolle ➝

ALUMINIUM · 3/2010

8. Weltmesse & Kongress 14. – 16. September 2010, Messe Essen

ALUMINIUM 2010

between innovation and environment Aluminium als Werkstoff ist stabil, korrosionsbeständig und leicht, lässt sich präzise verarbeiten, ist leitfähig und steht für hohe Ästhetik. Die hervorragenden Eigenschaften von Aluminium ermöglichen innovative Weiterentwicklung und visionäre Produktgestaltung – und helfen uns, die Umwelt zu schonen. Erleben Sie auf der ALUMINIUM 2010 die vielfältigen Anwendungsmöglichkeiten des Zukunftswerkstoffes Aluminium und seine Alleinstellung im Spannungsfeld zwischen Innovation und Umwelt. Wir sehen uns in Essen!

Organiser:

Institutional Patron:

Partner:

Official International Media Partner:

International Media Sponsor:

www.efp.de

www.aluminium-messe.com

ALUMINIUMrecycLINgINDUSTrIe

Sonderlegierung, mit Eisenwerten im normalen Primärbereich. Wir produzieren sie mit einer Umschmelzlegierung, die deutlich teurer ist, wenn man sie als Hüttenlegierung herstellt. Der Kunde hat uns bestätigt, dass unsere Umschmelzlegierung aufgrund der weiteren in ihr enthaltenen Komponenten sogar bessere Eigenschaften aufweist als das Primärmetall, das er vorher bezogen hat. Ein anderes Beispiel betrifft die Anfrage eines OEMs, der eine Aluminiumlegierung mit besseren dämpfende Eigenschaften wünscht. Bisher wurde die Legierung in Magnesium hergestellt. Wir arbeiten hier an einer Umschmelzlegierung aus Aluminium. Eine solche Entwicklung kann heute kaum ein Umschmelzer in Europa vorantreiben. Entweder

drei klassische Konverter als reine Warmhalte- und Legierungsöfen. Und natürlich steht eine aufwendige Ablufttechnik dahinter, um die Grenzwerte der TA Luft einzuhalten. Harzgerode ist ähnlich aufgebaut: mit zwei Trommelöfen in ähnlicher Größe wie in Gelsenkirchen, vier Konvertern und zusätzlich zwei Herdschachtöfen, weil wir aus der Produktion der Gusslegierungen große Mengen Kreislaufschrott zurückbekommen. Das ist Schrott, der beim Stanzen der Angüsse anfällt. Diese Herdschachtöfen können mit geringem Energieaufwand und Metallverlust diese eindeutig identifizierbaren Schrotte sofort wieder einschmelzen und das Metall für die Gussproduktion am Standort einsetzen.

F&E-Versuchsanlage in Essen

fehlt die F&E-Expertise oder der Link zur technischen Ebene der Automobilisten. Die Umschmelzer sind sehr kostengetrieben und haben in diesem Bereich in der Vergangenheit wenig oder gar nicht investiert. ALUMINIUM: Mit welcher Ofentechnik arbeiten Sie an den Recyclingstandorten? Reuther: Die beiden Umschmelzwerke in Harzgerode und Gelsenkirchen betreiben wir mit herkömmlichen Drehtrommelöfen unter Salz. Die genutzte Schmelzkapazität in Gelsenkirchen beträgt rund 50.000 Tonnen. Wir produzieren dort mit zwei Trommelöfen und vier Konvertern zum Auflegieren. Wir haben einen 30-Tonnen-Herdschmelzofen, um Festmetall zu schmelzen und

36

ALUMINIUM: Welche Produkte liefern Sie? Reuther: Für uns ist wichtig, eine breite Produktpalette anzubieten, das heißt Flüssigaluminium, Vorlegierungen, Desox-Aluminium für die Stahlindustrie und klassische Gusslegierungen, und dies nicht nur für die eigene Produktion, sondern für den Markt. Gelsenkirchen produziert fast ausschließlich für Dritte im Markt, Harzgerode – mit abnehmender Tendenz – zu 40 bis 50 Prozent für Dritte. Wobei Harzgerode in der Produktion deutlich wächst und dadurch mehr Aluminium im eigenen Kreislauf bleibt. Drei Viertel der Umschmelzproduktion, ohne den Standort Essen, geht an Externe. ALUMINIUM: Welchen Stellenwert

hat die Lieferung von Flüssigaluminium? Reuther: In Gelsenkirchen wird ein Kunde mit Flüssigaluminium beliefert. Wir wollen uns aber nicht zu abhängig von der Just-in-time-Belieferung mit Flüssigmetall machen. Außerdem wird unsere Gießerei in Harzgerode mit Flüssigaluminium versorgt. Das Schmelzwerk dort ergänzt sich gut mit der Gießerei. Wir setzen in Harzgerode rund 50.000 Tonnen Schrotte ein, die Produktion daraus geht zur Hälfte in die eigene Gießerei, die andere Hälfte wird für Dritte abgemasselt. ALUMINIUM: Stehen derzeit neue Investitionen im Recycling- oder Automotivegeschäft an? Reuther: Große Investitionen sind aktuell nicht geplant. Wir haben in Sömmerda interessante neue Aufträge im Bereich Mechatronic akquiriert. Dort haben wir in eine neue Druckgussmaschine investiert und ein neues Bearbeitungszentrum sowie ein neues Schmelzaggregat aufgestellt. An allen anderen Standorten arbeiten wir derzeit nach dem Motto „Cash is King“, geben nur dort Geld aus, wo der Markt einen schnellen Rückfluss bietet oder wo Ersatzinvestitionen notwendig sind. Wir haben in Harzgerode im Rahmen des Jointventures mit BMW die Kokillenproduktion gestartet. Hier kann es zu einem Kapazitätsausbau kommen, wenn sich weitere interessante Aufträgen ergeben. Grundsätzlich bin ich ein Befürworter „atmender Kapazitäten“. Unser Credo ist es, in Partnerschaften zu wachsen. Es macht keinen Sinn, in einer Industrie, die sehr investitionslastig ist und das Payback sehr spät erfolgt, immer wieder neue Kapazitäten aufzubauen, wenn die vorhandenen Kapazitäten im Markt ausreichen. So lassen wir im Einzelfall in Abstimmung mit unseren Kunden durchaus Produkte bei Dritten gießen. Die großen OEMs wollen vor allem einen Systemlieferanten, einen Ansprechpartner haben. Wenn man den Weg der Partnerschaften und Kooperationen geht, spart man Investitionen und kann mit den vorhandenen Kapazitäten atmen. ALUMINIUM: Können Sie auch dies beispielhaft konkretisieren? Reuther: Wir produzieren zum Bei-

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D U AS TL rU IMe I N I U M r e c y c L I N g I N D U S T r I e A LPU e M IcN II U

Ko

AK T NT

tiv planendes Unternehmen sind, mit dem man auch über neue Produkte sprechen kann, die vielleicht erst 2012 oder noch später starten. Und wo der Kunde sicher sein kann, dass sein Zulieferer Trimet Start-of-production und auch End-of-production erleben wird. Wir bieten die klassischen Stärken des Mittelstandes: kurze, schnelle Entscheidungswege, eine gesunde Finanzstruktur, ein marktnahes Management. Das hat in der Vergangenheit zu Neuaufträgen geführt und wird, da bin ich sicher, auch in Zukunft so sein. ■

UN T

ER

NE

H

Wä

AUToMoT iv

RMETAUscHER

EN

E

BA

U

i NdU

sTR

iE

ALUMINIUM · 3/2010

eher gestärkt als geschwächt aus der Krise hervorgehen. Das hat sich letztes Jahr gezeigt und sich Anfang dieses Jahres bestätigt. ALUMINIUM: Gestärkt aus der Krise – heißt das, auf die Schwäche der anderen setzen und auf eine Marktbereinigung hoffen? Reuther: So simpel möchte ich es nicht verstanden wissen. Aber gerade in Krisenzeiten zeigt sich im Markt, wo die Kompetenz und Stärke eines Unternehmens liegt. Der eine oder andere potenzielle Kunde erkennt und honoriert, dass wir ein konserva-

M

spiel ein Getriebegehäuse, das relativ hohe Zuwachsraten aufweist. Wir gießen das Produkt heute mit einer Maschine und es besteht die Aussicht, größere Mengen zu liefern, die wir mit dieser einen Maschine aber nicht bereitstellen können. Sollen wir nun zwei, drei Millionen in die Hand nehmen und eine weitere Maschine aufbauen, obwohl wir von anderen Unternehmen, zu denen wir ein partnerschaftliches Verhältnis unterhalten, wissen, dass sie über eine passende Anlage verfügen. Wir besprechen mit dem OEM dann, ob eine solche Partnerschaft akzeptiert wird, bei der wir Systemlieferant bleiben und für die Produktqualität haften. Das wird ganz transparent kommuniziert, ist ein durchlaufender Posten für uns, und allen ist geholfen. Der Kunde ist versorgt und hat auf diese Weise sogar ein Mehr an Ausfallsicherheit. Solche Kooperationen waren früher nicht vorstellbar, das ist von uns vorangetrieben worden. ALUMINIUM: Kommen wir nochmal zurück auf die Geschäftslage im Recyclingbereich der Trimet. Wie würden Sie die aktuelle Situation für Ihr Unternehmen charakterisieren? Reuther: Das reine Mengengeschäft entwickelt sich bei uns sehr gut, die Margen sind zufriedenstellend. Schrotte sind knapp verfügbar, das spiegelt sich auch im Preis wider, aber wir klagen auf einem akzeptablen Niveau. Auslastungsprobleme wie Anfang 2009, wo wir viel Metall der Börse angedient hatten, um nicht in Kurzarbeit gehen zu müssen, haben wir derzeit nicht. Trimet steht meiner Einschätzung nach besser da als viele Wettbewerber. Unsere Probleme sind beherrschbar. Wir werden

F. W. Brökelmann Aluminiumwerk GmbH + co. KG oesterweg 14 | 59469 Ense-Höingen Telefon: +49 (2938) 808-0 | www.broekelmann.com

T. T. Tomorrow Technology

ALUMINIUM recycLINg INDUSTry

Some of T. T.’s vehicles for the recycling industry: two scrap transporters, a coil transporter and the Multifunctional Furnace Tending Vehicles

T. T. Tomorrow Technology celebrates its 10th anniversary Spring of the year 2000 was the first time that T. T. Tomorrow Tech­ nology exhibited in public. This was at Metef when the new com­ pany, based nearby Padua in Italy, was launched to design and manu­ facture vehicles and equipment for the metals industry. T. T. came into being, with its official start in February of that year. “We wanted to give aluminium processing technology a shot”, recalls managing director Giovanni Campice. At that early stage it was not to be expected that the new venture would play such an important role in defining contemporary casthouses, recycling furnace management, anode cutting and slotting in smelters. From the very beginning, T. T. has always looked to the future, asking “What can be done better?” The answer has usually been a better way or new approach to metal processing technology. The new company soon led the industry in the development of many significant innovations, including the Multipurpose Furnace Tending Vehicles, which have changed the way furnaces are charged and cleaned, and the dedicated charging or de-drossing and furnace cleaning machines. In September 2001, T. T. launched the world’s first anode cutting machine. A few years later the powerful combination of anode handling technology with cutting know-how proved to be the foundation for the success of the anode slotting equipment. To chronicle all the events of the past ten years would take too long: T. T. has achieved many goals and

38

successfully entered many fields of competition, while innovations and moments of inspiration have made the company what it is today. Development has not only focused on markets and products, but also on expanding the company’s offices and workshops to meet the standards of an international first class company. Reliability, high profitability, ease of use and safety are recognised by customers as the main qualities characterising the products supplied by the Italian company. The most recent and important projects that T. T. completed include: • A by-pass anode handling line and an anode slotting line, supplied to Voerde Aluminium (formerly Corus Aluminium) in Germany • A Multifunctional Furnace Tending Vehicle to charge, de-dross and clean melting furnaces; and a rotating deck vehicle with 9.5 meters boom reach to de-dross and clean furnaces at Amag Casting in Austria; two similar vehicles were also supplied to the neighbouring company HAI Hammerer Aluminium Industries for their two plants in Ranshofen (Austria) and in Santana (Romania) • An automatic, rail-mounted furnace charging machine with rotating deck, mobile charging box with fully closed hood (to eliminate exhaust and smoke emission); and two fully automatic rail-mounted de-drossing machines were supplied for the new expansion of Eural Gnutti casthouse in Brescia (Italy). Identical machines were also supplied to the new Alumil billet plant in Kilkis (Greece) • A fully automatic, rail-mounted

ingot charging machine which works in combination with the ‘sister’ fully automatic de-drossing machine manufactured by T. T. have been in nonstop operation since August 2009 at the Fagor Plant in Spain. The reference list also includes the ‘jewels’ of the T. T. product range, notably the Multifunctional Furnace Tending Vehicles which have been manufactured for Germany, France, Norway, Turkey, The Netherlands, Luxembourg, and of course for Italy. Further main products in the T. T. range are: • Automatic charging machines for aluminium furnaces • Automatic, manual and radiocontrolled systems for de-drossing and cleaning aluminium furnaces • Liquid metal tapping and transport vehicles • Special vehicles for internal handling of aluminium coils and rolling mill rolls weighing up to 50 tonnes; • Aluminium scrap transport vehicles with a tilting charging box of 63 m3 capacity • Dross presses for aluminium dross treatment • Anode handling, cleaning, cutting and palletising lines; During 2010 T. T. Tomorrow Technology will be exhibiting on various occasions, starting in Italy at Metef (Montichiari-Brescia) in April. T. T. is also an exhibitor at the ALUMINIUM fair in Essen, Germany, in September. Both events will provide good opportunities to discuss the company’s new products and to exchange ideas and opinions with the visitors. ■

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D UA SL TU rMI IeN I U M A LPU e M IcN II U

recycLINg INDUSTry

remelting and refining modes in advanced recycling of wrought aluminium alloys, Part I In recent decades an increasingly large fraction of the world’s supply of wrought aluminium alloys has come from the aluminium scrap recovered from industrial waste and discarded consumer items. The reason for that is the creation of an additional net increase in added value during the produc­ tion of wrought alloys achieved through the consumption of in­ expensive raw materials. In other words, the common way of creat­ ing new added value inside the casting house is in substituting as far as possible costly and energy­ intensive primary aluminium and the alloying elements by cheaper and commonly available sources of aluminium alloys – preferably lower grades of scrap. However, replacement (of even a minor part) of primary aluminium in wrought alloys with the recycled counterpart originating from lower grades of scrap (typically scrap contaminated with various non-metallic impurities) – without at the same time influencing the quality of the alloy – is very demanding from the metallurgical point of view [1-7]. Developing a more complete understanding of the compositional tolerances in wrought aluminium alloys is still under investigation of many academic and industrial projects [8-10]. Recycled aluminium is produced by remelters and refiners. Refiners produce cast alloys and aluminium for deoxidation of liquid steel, while remelters produce wrought alloys. Casting alloys have a concentration of alloying elements of up to 20% while wrought alloys of up to 10%. Initially, remelters were distinguished from refiners by a lack of refining capability, but nowadays many remelters also practice refining and filtering of their recycled metal in order to make it competitive with primary metal, even for very demanding applications. As the demand for clean scrap from

ALUMINIUM · 3/2010

other recyclers increases its price, remelters increasingly start consuming lower grade scrap to meet their needs. Because the use of lower grade scrap makes quality control more demanding, refining and purification are becoming steps regularly practised by producers of wrought alloys [11]. Remelters must select the appropriate quantity and quality of scrap to suit the chemical composition of the wrought alloy to be produced. Hence, extra care must be taken to keep the different aluminium alloys separate. In practice, there are two different approaches for achieving the required chemical composition of wrought alloys made from recycled aluminium: • before melting, by combining the appropriate qualities and quantities of scrap, primary aluminium and the alloying elements • during melting, by diluting the impurity content with primary aluminium to the needed level and, at the same time, adding the amount of alloying elements necessary to achieve their standard concentration in the diluted melt. Evidently, technique of achieving of the proper chemical composition of wrought alloys before melting is more profitable, but also much more demanding from the viewpoint of scrap pre-screening, optimal pre-sorting and separation. For typical production (melting performed in real time) this procedure is also less flexible regarding the chemical composition of the available scrap, sorting and scrap allocation due to the overall requirement for minimal consumption of primary metal and alloying elements. It is important to note that the new added value created by this procedure depends strictly on the successful replacement of primary aluminium and alloying elements by a cheaper input composed of different alloy blend obtained by careful selection and mixing of various scrap materials. The decisions regarding what scrap material to use, which and how much to sort and,

V. Kevorkijan

V. Kevorkijan, Maribor

Varužan Kevorkijan, independent researcher, located in Maribor, Slovenia

finally, allocating the compositions which are to be produced are crucial for achieving sufficient flexibility and economic benefits. On the other hand, it is important to note that adjustment of the proper chemical composition of wrought alloys during melting (better known as ‘sweetening’ of the melt with primary aluminium) is a common production practice by most traditional remelters around the world. For refiners it is common practice to mix different alloys with alloy-specific scrap batches before loading the scrap into the furnace. Because wrought alloy scrap cannot be used to produce new wrought alloy unless one or more of the impurities are diluted by the addition of primary metal, it is difficult to expect that the refining mode for production of wrought alloys will prevail until the development of technology for segregating scrap by alloy type; the commercial use of this technology is currently in its infancy. Thus, a significant breakthrough in the future would be necessary for completing the initial evolution of existing remelters of wrought alloys into refiners, willing to separate raw material of uncertain chemistry into well defined batches, and blend appropriate proportions of them ➝

39

ALUMINIUM

ALUMINIUM recycLINg INDUSTry

Clean high-grade scrap of wrought aluminium alloys

to produce a consistent wrought alloy with the required chemistry at the lowest possible cost. The benefits of production of wrought aluminium alloys from low grade scrap In recent years recycling of low grade scrap has become an increasingly important issue of metal supply for both casting and wrought alloys. Looking to the future, production of recycled aluminium of standard quality from the cheapest sources will play an increasingly significant role in the growth of the European aluminium industry. Despite the economic slowdown, the consumption of primary aluminium in the EU is expected to increase to eight million tonnes by 2012, while European production of primary aluminium is expected to decrease gradually down to 2.86 million tonnes by 2012. The gap between the expected production of primary aluminium and its consumption of about 5.24 million tonnes will be covered by imports and recycling inside the EU. At the same time, the continuous increase in the relative proportion of recycled versus primary aluminium sources will be driven by the pressure to improve business results and striving for individual profit maximisation. Additional, very important benefits of recycling aluminium from low grades scrap are: • spreading the risk of a potential shortage of raw materials by diversifying the supply sources of aluminium

40

away from exclusively primary metal and clean scrap suppliers • an improvement in logistics – ensuring an appropriate and cost effective supply from different scrap sources. Others advantages of recycling low grades of aluminium scrap are the additional energy savings and higher compositional flexibility in combination with clean grades of scrap and dross. For several decades, a kind of belief existed in the aluminium industry that the standard quality of wrought alloys could be achieved only by combining a sufficient amount of primary aluminium, internal scrap and only clean, well sorted external scrap. Consequently, ingots made from primary aluminium, internal scrap and clean industrial or external old scrap (single wrought alloy with less than 2 wt.% of non-metallic impurities) were obligatory in the mass production of wrought alloys as the only source of the new and recycled aluminium capable of assuring the standard quality of end products. Scrap for the production of wrought alloys should be sorted with strict control of the concentration of alloying elements in order to achieve the prescribed compositional tolerances [12]. An additional problem is caused by the very limited ability of wrought alloys to tolerate elements not normally present in their composition. In other words, well defined wrought scrap of the proper composition could be effectively remelted into a wrought alloy of the same composition, but it

is very demanding to achieve a new wrought composition by direct reuse, without addition of primary metal and alloying elements. The addition of primary aluminium is necessary to dilute impurities (elements not normally present in wrought alloy) to an acceptable level, while alloying elements are added, if necessary, for correction of their concentration. Thus, most external scrap inside the EU (above 60%) is preferably applied for the production of casting alloys and only the remainder is dedicated to remelting. Although non-metallic impurities can also significantly influence the quality of the molten metal, it is not obligatory that scrap for wrought alloys should be clean, without organic and other non-metallic impurities, if these could be effectively removed before or during the recycling procedure. Some of the advanced melting furnaces, such as various rotary or multi-chamber units, enable the direct melting of highly contaminated scrap (e. g. painted and lacquered) with thermal de-coating and recycling occurring consecutively. Moreover, in internal technical documentation for the production of wrought alloys, more or less empirical compositions were often established, resulting in production mixtures with the prescribed amount of primary aluminium, internal, industrial external and old external scrap. However, it is important to note that such empirical compositions are usually adapted to the common availability of various raw materials and in many cases are below the real potential of possible re­ placement of primary aluminium by scrap without influencing the standard quality of the final products. The problem is that in many cases these empirical compositions are also approved by the customers, becoming in that way a contractual obligation of the producer of alloys. On the other hand, it is well known that for aluminium alloys (especially wrought alloys) a practical ‘compositional tolerance limit’ exists and a fairly complete knowledge of these tolerance limits for all elements is needed, especially in recycling operations where unexpected and unusual

ALUMINIUM · 3/2010

S AMLr e c y c L I N g I N D UA SL TU rMI IeN I U M A LPU e M IcN II U impurities can creep in inadvertently, and even normal impurities may tend to accumulate and build up to a disastrous degree. In most cases, the influence of these tolerance limits for various elements and various combinations of elements on the properties (and particularly on selected properties) of wrought alloys is not well investigated. Because of that, customers often require more narrow com­ positional tolerances than are necessary, creating unnecessary losses for themselves and the casting house. Customers lose an important part of the competitiveness of their products in downstream business activities by paying more for non-optimal tolerance limits and, at the same time, the casting house loses the added value by producing alloys from more expensive inputs. As an example, the average new added value created by producing wrought alloys from external contaminated scrap is about 7% of LME. For aluminium dross in the form of pressed skulls the new added value is significantly higher and could reach approximately one third of LME (considering pressed skulls as internal scrap). Difficulties in recycling existing wrought aluminium alloys As already mentioned the main difficulty in production of wrought aluminium alloys from scrap is to achieve the proper chemical composition of the melt with minimal addition of primary aluminium and alloying elements. Technically, the problem is in the missing technology (an economically acceptable chemically based refining process) for reducing the concentration of critical alloying elements such as copper, iron, manganese, silicon and zinc, in a melt batch produced from various sorts of scrap. Once the concentration of these critical elements in the melt is above the concentration limit for a particular wrought alloy, the only practical solution would be their dilution by primary metal. Another technical solution is to avoid incorrect melt composition by carefully predicting and assuring the

ALUMINIUM · 3/2010

recycLINg INDUSTry

chemical composition of the batch in a pre-melting stage of casting. In principle, there is also a third solution: convince the customers to accept the so-called ‘recycling friendly wrought alloys’ – in other words, alloys with broad compositional tolerance limits and, consequently, to some extent of different quality to cost ratio. This could be an important future trend in developing new wrought alloys, working hand in hand with customers in implementation of their requirements to scrap-friendly compositions [1-4], but for the existing alloys and existing customer demands such an approach has definitely a quite limited potential and is also too risky. In most of today’s plants, the predominant mode of recycling – more accurate scrap blending or very strict melt dilution is decided by the margin between recycled metal and primary aluminium. However, it is important to note that this margin – the difference in price of primary aluminium (which is determined globally) and the recycled metal (which is calculated locally) – is affected by internal and external circumstances. Among internal factors the most important are: • permanent and stable sources of new and old scrap, concentrated sufficiently in one area to justify the cost of collecting • a scrap collecting and sorting infrastructure including devices for removing impurities and delivery to a recycling plan • a method of recycling that is economically competitive with production of primary aluminium • a market willing to accept the composition and the quality of wrought alloys made from scrap. More expensive, clean and sorted scrap (mainly new or industrial scrap) contains a minimal concentration of critical elements, while in old scrap of lower cost it becomes more critical. In typical municipal old scrap, which is a cost-effective source of aluminium, the minimal concentration of critical elements (silicon, iron, copper, manganese, zinc, magnesium) is typically too high for direct remelting into wrought compositions without dilution by primary aluminium, see Table 1.

On the other hand, in new scrap resulting from the collection and/or treatment of the metal that arises during the production of aluminium products before these are sold to the final users, the right alloy composition is assured in advance; however, the cost of such scrap is significantly higher and its availability is usually limited to closed production loops. Element Fe Si Cu Mn Zn Mg Cr Ni Pb Sn Bi Ti

Concentration (%) 0.60-1.00 0.30-9.00 0.25-4.00 0.60-1.50 0.25-3.00 2.00 0.05-0.30 0.04-0.30 0.02-0.25 0.02-0.30 0.02-0.30 0.05-0.25

Table 1: Typical concentrations of the main alloying elements in old municipal old scrap [13]

The economics of contaminated wrought scrap recycling The economics of wrought aluminium alloys recycling from scrap is specific and differs from the economics of cast alloys recycling since cast alloys have higher compositional tolerance limits for impurities and can absorb a wider variety of scrap. During the production of cast alloys from scrap of various compositions, refiners are able to add alloying elements and remove certain unwanted elements after the melting process. Cast alloys tend to have higher alloy content than wrought alloys and because of that are difficult to recycle into anything other than cast alloys, since the removal of most alloying elements from molten aluminium would be impractical. On the other hand, wrought scrap cannot be used to produce new wrought alloys unless separated by alloys or alloy groups and/or diluted by the addition of primary metal. In this regard, a possible way of improving the recycling of wrought aluminium alloys is the use of new and old scrap with higher amounts of organic impurities. Most aluminium scrap mixtures currently used ➝

41

ALUMINIUM recycLINg INDUSTry

for the production of wrought aluminium alloys from low grade scrap have an organic impurities content lower than 8 wt.%. The most common organic impurities are oils, polymers such as polyester and epoxy, rubber, lacquers, paints, etc. In some heavily contaminated aluminium scrap, the organic impurity level exceeds 18 to 20 wt.%, while in clean industrial scrap the non-aluminium impurity level is usually less than 2 wt.%. The main reasons to start using contaminated instead of clean scrap for production of wrought aluminium alloys are in improved added value (net profit surplus achieved per weight unit of aluminium or aluminium alloys of standard quality recycled from low quality aluminium scrap) and better logistics (scrap sourcing, availability on the market and improved flexibility in supplying). The key advantage is in the fact that the cost of contaminated scrap is significantly lower than the cost of clean scrap of the same pre-sorting quality (e. g. single alloy or single series grade), in that way providing an opportunity for producing aluminium wrought alloys of the standard quality and with improved competitiveness. The prerequisite for that lies in appropriate performance of the entire recycling process, from the scrap sourcing and purchasing strategy to the complete recovery of all by-products, in order to achieve the standard quality of recycled aluminium and the proper economy. In practice, irrespective of the fact that the recycling of contaminated scrap is more demanding and costly than remelting of clean scrap, the total cost per weight unit of recycled aluminium or aluminium alloy of standard quality produced from contaminated scrap is lower than the cost of the remelted aluminium or aluminium alloy counterpart produced from clean scrap which is nowadays much in demand for the production of wrought alloys. As a rule, clean scrap (e. g. scrap with a minimum of 98% of Al) represents a costly raw material for the production of wrought alloys. Its market price is close to the theoretically expected, calculated according to the aluminium content and cost of recovery. Therefore, the usage of

42

clean scrap in production of wrought alloys provides only limited possibilities for creating new added value or, in another words, for lowering of the cost of the impute. Typically, the market prices of clean scrap of a single wrought alloy vary slightly below or above the price of the counterpart ingots, depending on their market availability. On the contrary, the market price of contaminated scrap (scrap with e. g. 80% of Al and 20% non-metallic, mostly organic impurities) ranges significantly (10-25%) below the theoretically expected based on the aluminium content and cost of recovery. Thus, taking into account the cost of recycling and all related costs, the total cost of production of recycled aluminium alloy fabricated from clean scrap would usually be near the cost of melting the same alloy from primary aluminium (including the cost of the appropriate alloying elements). In contrast to that, by using less clean scrap (scrap contaminated with organic impurities) and applying the proper recycling technology, some higher net added value (typically between 5 and 10%) can be achieved. It is important to note that the significant part of the new added value is gained by the successful buying of less clean grades of scrap. Hence, it is necessary to understand the local new and old scrap market and organise cost-effective buying from the nearest scrap suppliers or though collecting new scrap. The second part of the new added value is achieved in the process of scrap separation, where an optimal level and method (e. g. hand sorting or automatic screening) of separation should be selected following the compromise between the degree of compositional separation and the cost of achieving it, also taking into consideration that a lower level of compositional separation leads during final melting to the higher consumption of primary aluminium for diluting impurities. Of all the sorting technologies, hand sorting remains the most common method of recovering aluminium. Because a load of mixed scrap (even new, industrial) often includes a limited number of alloys, hand sorting

often makes it possible to produce single alloy scrap products. Even if this is not possible, hand sorting can help meet specifications for other scrap grades by removing impurities. Often, a dealer’s experience and knowledge of his suppliers is useful in hand sorting, because the appearance of a piece of new scrap – the shape of a punching, the type of scrapped part – will be sufficient to identify the alloy. Finally, the remaining part of the new added value depends on the competitiveness of the selected remelting technology, which should be able to provide the highest metal yield, a standard quality of the molten metal and operating in accordance with standard environmental regulations. references 1. D. G. Altenpohl, P. Paschen, ALUMINIUM, 77 (1/2) (2001) p. 8. 2. S. K. Das, Materials Science Forum, Vols. 519-512 (2006) p. 1239. 3. S. K. Das, In: Light Metals 2006, Ed. T. J. Galloway, TMS-AIME, Warrendale, PA (2006) p. 911. 4. S. K. Das, Aluminium Recycling and Processing for Energy Conservation and Sustainability, Ed. J. A. S. Green, ASM International (2007) p. 147. 5. R. Hirve, Metalworld, Vol. 8, No. 3 (2009) p. 32. 6. R. E. Sanders, Jr., JOM, 53(2) (2001), p.21. 7. J. B. Hess, Metal. Mater. Trans. A, 14(2) (1993) p. 323. 8. D. G. Altenpohl, Aluminium: Technology, Applications, and Environment, 6th ed., TMS-AIME, Warrendale, PA (1998) p. 15. 9. G. Rombach, In: Light Materials 2002, Ed. W. Schneider, TMS-AIME, Warrendale, PA (2002) p. 1011. 10. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway, NW (2007) p. 9. 11. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway, NW (2007) p. 171. 12. Aluminium Association, International Ally Designation and Chemical Composition Limits for Wrought Aluminium and Wrought Aluminium Alloys, Aluminium Association, Arlington, VA (2009). 13. M. E. Schlesinger, Aluminum Recycling, CRC Press, Broken Sound Parkway, NW (2007) p. 101.

To be continued in ALUMINIUM 4/2010

ALUMINIUM · 3/2010

Technology

Hochbetrieb in der Werkstatt von Danieli Fröhling

ALUMINIUM

Das Krisenjahr 2009 gut gemeistert

In der Montagewerkstatt von Danieli Fröhling in Meinerzhagen herrscht derzeit Hochbetrieb Inside the Danieli Fröhling assembly shop in Meinerzhagen, now working busily

A busy time in the Danieli Fröhling workshop

The crisis year 2009 overcome well Whereas 2009 was one of the most difficult business years ever for machinery and plant engineering, with drastic order cut-backs, a few such equipment manufacturers are beginning to see signs of a modest market recovery. A lot of work is now going on in the workshop of the rolling plant manufacturer Danieli Fröhling in Meinerzhagen, Germany, to assemble various machines and plant components to the required quality in time for a series of scheduled delivery dates. This relates mainly to three major contracts: a coldrolling plant for the steel industry, but also two trimming and slitting units for the aluminium industry. During a visit to the workshop of Danieli Fröhling in Meinerzhagen, managing director Jörg Schröder seemed reasonably satisfied with the present order status of his company: “The market is again showing some signs of life after last year, which was marked by many project postponements. Since then, projects shelved in the copper and aluminium branches have been revived again.” On the other hand, there is still silence, as it

ALUMINIUM · 3/2010

were, from the stainless steel sector because of substantial overcapacities in the market. The impetus for new equipment still comes mainly from China in both the copper and aluminium sectors. South America is also promising. In the past year Danieli received an order from Termomecanica São Paulo, market leader for the production of long and flat copper and copper-alloy products in the South American market, for the construction of a prerolling mill and a finish-rolling mill for strip widths up to 600 mm, and for a milling machine. The Russian market, however, has not so far lived up to expectations, right across the sector; there, hardly any projects are currently in progress. The market in Europe and Germany is characterised by modernisations of existing plants more than anything else. Danieli Fröhling managed to cope with last year in a more balanced way than many of its competitors. Since its order books were well filled, the company was able to keep going throughout the year without having recourse to short-time work. In fact, over the past 18 months the company has even taken on 15 new and ➝

Während 2009 eines der schwierigsten Geschäftsjahre für den Maschinen- und Anlagenbau mit drastischen Auftragsrückgängen war, spürt der eine oder andere Anlagenbauer wieder eine leichte Belebung des Marktes. Beim Walzwerkbauer Danieli Fröhling gibt es derzeit eine Menge Arbeit in der Werkstatt in Meinerzhagen, um pünktlich zu anstehenden Lieferterminen verschiedene Maschinen und Anlagenkomponenten qualitätsgerecht fertig zu stellen. Das betrifft vor allem drei große Aufträge: ein Kaltwalzwerk für die Stahlindustrie, aber auch zwei Besäum- und Längsteilanlagen für die Aluminiumindustrie. Bei einem Besuch der Werkstatt von Danieli Fröhling in Meinerzhagen zeigte sich Geschäftsführer Jörg Schröder mit der derzeitigen Auftragslage seines Unternehmens einigermaßen zufrieden: „Wir spüren, dass wieder etwas Leben in den Markt kommt, nachdem das vergangene Jahr vielfach von Projektverschiebungen gekennzeichnet war. Inzwischen werden die in der Kupfer- und Aluminiumbranche auf Eis gelegten Projekte wieder aufgegriffen.“ Im Edelstahl herrsche dagegen aufgrund von erheblichen Überkapazitäten im Markt noch immer Funkstille. Die Impulse für Neuanlagen kommen weiterhin vor allem aus China, sowohl auf der Kupfer- wie auf der Aluminiumseite. Daneben bleibt Südamerika aussichtsreich. So wurde Danieli im vergangenen Jahr von Termomecanica São Paulo, dem Marktführer in der Herstellung von Langund Flachprodukten aus Kupfer und Kupferlegierungen im südamerikanischen Markt, mit dem Bau eines Vorwalz- und eines Fertigwalzwerks für Bandbreiten bis 600 mm sowie einer Fräse beauftragt. Der russische Markt hat die Erwartungen, und zwar der gesamten Branche, bisher nicht erfüllt; hier sind kaum aktuelle Projekte in Bearbeitung. Der europäische und deutsche Markt ist eher durch die Modernisierung bestehender Anlagen gekennzeichnet. Danieli Fröhling konnte das vergangene Jahr ausgeglichener als ➝

43

Technologie

mancher Wettbewerber meistern. Da die Auftragsbücher gut gefüllt waren, gelang es dem Unternehmen, das Jahr ohne Kurzarbeit zu fahren. In den letzten eineinhalb Jahren wurden sogar 15 neue hoch qualifizierte Fachkräfte für alle Unternehmensbereiche eingestellt. Einige der Ingenieure sind in Poole angesiedelt, dem Centre of Competence für die gesamte Aluminiumwalzwerkssparte bei Danieli Fröhling. Der Blick in die Werkstatt wird zunächst dominiert von der Montage eines Quarto-Reversier-Kaltwalzwerks für hochfeste Stähle, das von der österreichischen Böhler Uddenholm in Auftrag gegeben war. Die Anlage ist für Bandbreiten von max. 670 mm und Coil-Gewichten von 16 Tonnen ausgelegt. Die Anlagengeschwindigkeit beträgt max. 800 m/min, die Walzkraft max. 12.000 kN und die installierte Antriebsleistung 6.600 kW. Daneben wird derzeit eine Hochgeschwindigkeits-Besäum- und Längsteilanlage für Shandong Nanshan Aluminium Co., Ltd. und eine für Shanghai Datun Energy Ressources Co., Ltd. montiert, die beide für Aluminiumbänder der Legierungsgruppen 1xxx, 3xxx, 5xxx und 8xxx vorgesehen sind. Die Anlage für Shanghai Datun ist für Banddicken zwischen 0,10 und 1,0 mm und Bandbreiten zwischen 900 und 2.150 mm bei CoilGewichten bis 20,7 Tonnen ausgelegt. Die Anlagengeschwindigkeit beträgt max. 1.200 m/min, zum Einsatz kommt eine CNC-Kreismesserschere, Anzahl der Fertigstreifen: 2. Die Anlage für Shandong Nanshan ist für Banddicken zwischen 0,15 und 1,0 mm und für Bandbreiten zwischen 900 und 2.100 mm bei CoilGewichten bis 28 Tonnen ausgelegt. Die Anlagengeschwindigkeit beträgt max. 1.500 m/min, zum Einsatz kommen eine CNC-Besäumschere und Längsteilschere, Anzahl der Fertigstreifen: 3. Für die Besäum- und Längsteilanlage für Shandong Nanshan wird zudem eine elektro-statische Einölmaschine montiert, deren Highlight die feine Zerstäubung und hohe Transportgeschwindigkeit des Ölfilms ist, was wiederum zu einer gleichmäßigen

44

Ölverteilung auf der Bandoberfläche führt. Das Tankvolumen beträgt 2 x 300 Liter, die Beschichtungsgeschwindigkeit 100 bis 400 mg/m2 je Seite. Drei solcher Systeme befinden sich bereits in Auftrag bzw. kurz vor Beginn der Produktionsphase. Danieli Fröhling sieht sich heute aber nicht mehr als ein Komponentenhersteller für die Aluminiumindustrie, sondern tritt in Verbindung mit den Schwesterfirmen Danieli Automation und Danieli Wean United als Single-Source-Anbieter von schlüsselfertigen Komplettanlagen auf – von Warmwalz- über Kaltwalz- bis hin zu Folienwalzwerken mit allen dazugehörenden Behandlungseinheiten inklusive der kompletten Elektrik und Automation. Der Markenbegriff „Diamond Mill“ unterstreicht dabei den Anspruch des Unternehmens, sich als Premiumanbieter mit hochwertigen Anlagen im Markt zu etablieren. Die Kooperation mit Innoval Technology, einem Spinoff der früheren Alcan mit Expertise im Betreiben von Walzwerken, trägt dazu bei, Walzwerkstechnik sowohl aus Sicht des Maschinen- und Anlagenbauers wie auch aus Betreibersicht zu konstruieren. Dies macht Danieli gerade auch für Unternehmen interessant, die keine langjährige eigene Erfahrung im Walzen von Aluminium aufweisen. Hier kann der Partner Innoval das nötige Produkt- und Prozess-Knowhow einbringen. Schröder betont bei diesem Anspruch, nicht auf Biegen und Brechen an Ausschreibungen teilnehmen zu wollen, um schnell eine Referenzanlage vorweisen zu können. „Wir geben nur dort Angebote ab, wo wir sicher sind, eine intensive Betreuung des Kunden von Anfang der Projektphase an sicherstellen zu können“, sagt er. Bei der Ausschreibung eines Kaltwalzwerks in China war Danieli Fröhling bis in die Endphase vertreten. Schröder unterstreicht, dass diese Ausschreibung eine hervorragende Gelegenheit war, das „Diamond“Konzept praxisnah zu verfeinern und auf den Kundenbedarf auszurichten. Auch das Konzept für Folienwalzwerke wurde inzwischen so verfeinert, dass man sich im Wettbewerb gut gerüstet sieht. Schröder nennt in ➝

highly qualified staff across the organisation as a whole. Some of the engineers are settled in Poole, the location of the Centre of Competence for the entire aluminium rolling plant sector of Danieli Fröhling. The view in the workshop is primarily dominated by the assembly of a 4-high reversing cold mill for highstrength steels, ordered by Böhler Uddenholm. The unit is designed for strip widths up to 670 mm and coil weights of 16 tonnes. The maximum speed of the machine is 800 m/min, the rolling force up to 12,000 kN and the installed drive power is 6,600 kW. In addition, at present a highspeed trimming and slitting machine is being assembled for Shandong Nanshan Aluminium Co., Ltd and one for Shanghai Datun Energy Resources Co., Ltd, both of them for aluminium strips of the alloy groups 1xxx, 3xxx, 5xxx and 8xxx. The machine for Shanghai Datun is designed for strip thicknesses between 0.1 and 1.0 mm and strip widths between 900 and 2,150 mm, with coil weights up to 20.7 tonnes. The maximum machine speed is 1,200 m/min and it uses a CNC circular blade shear. Number of finished strips: 2. The machine for Shandong Nanshan is designed for strip thicknesses between 0.15 and 1.0 mm and strip widths between 900 and 2,100 mm, with coil weights up to 28 tonnes. The max. machine speed is 1,500 m/min and it uses a CNC trimming and slitting shear. Number of finished strips: 3. For the Shandong Nanshan trimming and slitting unit an electrostatic oiling machine is also being assembled, whose highlight is the fine spraying and high transport speed of the oil film, which in turn results in uniform oil distribution over the strip surface. The tank volume is 2 x 300 litres and the coating rate is 100 to 400 mg/m2 on each side. Three such systems have already been ordered or are shortly before the beginning of their production phase. What’s more, today Danieli Fröhling no longer regards itself as a component manufacturer for the aluminium industry, but rather, in combination with its sister companies Danieli Automation and Danieli Wean ➝

ALUMINIUM · 3/2010

technologie

customer’s needs. United, as a single-source supplier of diesem Zusammenhang die technolocomplete, turnkey plants – from hotgisch hochwertige Steuerung, mit der The concept for foil mills has meanrolling, to cold- and foil rolling mills sich verändernde Eingangsparameter while also been refined to the point in die Planheitsregelung gegenüber that the company is well equipped to with all the associated treatment units compete. In this connection Schröder heutigen Systemen wesentlich verbesand including the complete electrical mentions the technologically highand automation and process systems. sert werden. So werden die Eingangsgrade control system with which varThe trademark ‘Diamond Mill’ parameter für mathematische Modelying input parameters for the flatness emphasises the company’s aim to le durch das neu entwickelte ‘Hi-Res regulation have been substantially have established itself on the market Spray System’ konstant gehalten und improved compared with current sysas a premium supplier of high-grade somit höhere Genauigkeiten über die tems by applying the new developed equipment. Its collaboration with InWalzzeit erreicht als bei traditionellen ‘Hi-Res Spray System’ and therefore noval Technology, a spin-off from Modelle. Neue Folienwalzwerke wird quality fluctuations originating in that the former Alcan with expertise in es in Europa künftig seltener geben, way are reduced for constant input aber auch die Modernisierung bestethe operation of rolling plants, convalues for the mathematical models. hender Anlagen ist für Danieli Fröhtributes much to the design of rolling In Europe it is unlikely that ling interessant, „weil man new foil mills will often apdabei technologische Highpear in times to come, but for lights setzen kann, womit wir Danieli Fröhling the modunserem Anspruch als Preernisation of existing units miumanbieter gerecht weris also interesting, “because den können. Insofern ist das in doing this one can achieve Modernisierungsgeschäft ein technological highlights attraktives Segment, das wir which justify our claim to be ebenfalls selektiv verfolgen“, a premium supplier. Accordso Schröder. ingly, modernisation busiImmer wichtiger beim ness is an attractive sector Bau von Walzwerken wird which we also pursue selecdie nachgeschaltete Ablufttively”, Mr Schröder says. reinigung. Auch in aufstre- Grafische Gesamtansicht der Besäum- und Längsteilanlage für Abb.: Danieli Fröhling benden Regionen wie Asien Shandong Nanshan Aluminium Of continually increasing und Südamerika gewinnt Overall view of the trimming and slitting unit for Shandong importance when building eine moderne Luftrein- Nanshan Aluminium rolling plants is the downhaltetechnik mit strengen stream exhaust air purificaEmissionsgrenzwerten wachsende tion. Even in developing regions such mill technology having regard to the Bedeutung. Hier ist Danieli Fröhling as Asia and South America modern standpoints of both the machinery vor kurzem eine exklusive Kooperaair purification technology with and plant manufacturer and the option mit der Julius Montz GmbH aus strict emission limit values is gainerator of the plant. This makes Danieli ing importance. In this field Danieli particularly interesting for companies Hilden eingegangen, die sich auf den Fröhling recently set up an excluwhich do not have long years of their Vertrieb und die Weiterentwicklung sive collaboration with Julius Montz own experience in the field of aluminder DAN-ECO2-Systeme erstreckt. GmbH in Hilden, which extends to ium rolling. In such cases the partnerDas Unternehmen ist international für the marketing and further developship of Innoval can provide the necesseine Konstruktion von Abluftreiniment of the DAN-ECO2 systems. The sary product and production process gungssystemen bekannt. DAN-ECO2 know-how. wird zur effizienten Rückgewinnung company is internationally known for In this context Schröder stresses und Rückführung von gebrauchtem its design of exhaust air purification that he has no wish to participate in Walzöl in den Walzprozess eingesetzt systems. DAN-ECO2 is used for the eftenders by hook or by crook in order und schützt die Umwelt vor flüchficient recovery and refeeding of used tigen organischen Verbindungen. Bei rolling oil during the rolling process to be able as quickly as possible to einem Abgasstrom von 120.000 m3 and protects the environment from point to reference plants. “We only volatile organic compounds. With an tender when we are confident that we pro Stunde und 1.000 mgC/m3 reiexhaust gas flow of 120,000 m3 per can serve the customer’s needs comnigt die Anlage mit einer Effizienz pletely from the very beginning of the von 99,95 Prozent. Eine solche Anhour and 1,000 mgC/m3, the unit planning phase”, he says. In tendering lage wird unter anderem im Hydropurifies with an efficiency of 99.95 for a cold mill in China Danieli FröhWalzwerk in Grevenbroich eingepercent. Such a unit is in use at the ling was represented right up to the setzt. Eine bessere Anlagenreferenz Hydro rolling plant in Grevenbroich, final phase. Schröder stresses that the in einem Land, dessen Emissionsamong others. There can be no better tender in question was an outstandgrenzwerte zu den strengsten in der plant reference in a country whose ing opportunity to further refine the Welt zählen, kann es nicht geben. emission limit values are among the ‘Diamond’ concept and adapt it to the strictest in the world. ■ ■

46

ALUMINIUM · 3/2010

Technology

Technology breakthrough in the production of aluminium ingots B. Rieth, Meerbusch

Track & Belt is the latest and the natural evolution of the casting wheel technology, which decisively bears the Properzi stamp and has proved its worth for years. To give the dimensions usual for ingots, already since the early 1990s the company adapted the introduced and proven process by enlarging and the cast cross-section and the casting wheel diameter up to 4.2 m for the production of ingots from secondary aluminium. Whereas the solidification process takes place in the casting wheel around part of the wheel circumference covering an angle of 210 degrees with a U-shaped mould cross-section covered by a circulating steel strip, in the case of Track & Belt the casting wheel is replaced by a mould made from a special copper alloy, which is divided into a number

ALUMINIUM · 3/2010

of individual segments that follow one another closely. The segments are mounted on a circulating endless chain and are moved in the solidification zone horizontally, interlocked with one another. This succession of segment can be ideally seen as a casting wheel cut into small segments with radius equal to ‘infinity’. Thus, the length of the solidification zone is no longer determined by the diameter of a casting wheel but can be chosen freely, which results in a substantial production performance increase. The tension chain with the mould segments attached on it passes round two gearwheels, one of which is driven, and pulls the individual moulds at a speed which is adjustable in accordance with the solidification process taking place in the solidification zone. During this the mould blocks are covered by a circulating steel strip, so that

trapezium-shaped, emerges from the machine. A secondary bar cooler provides further cooling of the bar down to 450°C to 520°C before passing in the down stream equipment. This is first marked with all the data required for identification, before being cut up automatically by a rotary shear into individual ingots with a reproducible length, usually 720 mm, with a tolerance of ±0.5 percent. The ingots are cooled in a cooling tunnel down to 60° to 70°C and then automatically stacked in layers by a Cartesian stacker, strapped and labelled. Compared with ingots cast conventionally in open moulds, those produced by a Track & Belt unit differ in having smooth and flat surfaces on which no moisture collects during storage. They are also free from dross inclusions and cavities. The stacks, with several layers offset relative to one another by 90 degrees, are of stable shape and require very little effort to strap. Besides, several stacks can be stored one on top of another. Must aluminium ingots always weight 22.7 kg?

Photos: Vedani Carlo Metalli

Ingots are the most usual form in which, after melting, aluminium is supplied to the industry. Such ingots have long been produced in horizontal, trapezium-shaped moulds open at the top, of which several are connected to one another to form endless units, and go through a discontinuous casting process in cycles. The standard size of 50 lb (22.7 kg) has become established on the market. The Italian manufacturer ContinuusProperzi S.p.A., successful since the 1940s all over the world in the development and production of more than 300 continuous casting and direct rolling systems for the production of non ferrous wire rod, has years ago been seeking a method for producing ingots continuously as sections of an endlessly cast strand. From an intermediate step with a casting wheel diameter enlarged to 4.2 metres, a new technological concept called ‘Track & Belt’ has been developed. In this, smooth and safely stackable aluminium ingots are produced from a horizontally cast endless strand, cut into reproducible lengths with close tolerance limits.

View of a Properzi Track & Belt line in operation

a temporarily closed mould cross-section is created. The molten metal flows in a controlled way, automatically and free from turbulence, out of the tundish and into the moulds formed by the copper segments and the steel strip. External cooling-water nozzles arranged on all sides ensure rapid and uniformly controlled solidification. At the end of the horizontal solidification stretch a cast strand, already straight by virtue of the casting process and

On this point we spoke to Carmelo Maria Brocato, commercial director at Continuus-Properzi. ALUMINIUM: What caused Properzi to call into question the shape and weight of aluminium ingots that have been customary for so many years? Brocato: That began in the 1990s, when the Italian company Raffmetal, which has since grown to become the largest refiner in Europe, was looking for a more efficient system for producing ingots weighing 8.5 kg. For Properzi, therefore, it was clear from the start that in connection with the development of a new technology a way also had to be found to eliminate the known problems associated with open-mould casting, in other words dross inclusions, cavities and limited reproducibility of the dimensions and weight. ALUMINIUM: How much were you able to have recourse to your tried ➝

47

Technology

and tested casting wheel technology? Brocato: As you know, our continuously-operating casting wheels were originally designed for the production of pre-material for aluminium and copper wires, in other words for comparatively small cross-sections and production quantities. Larger cross-sections and higher throughput performances require as a first step that the mould cross-section and the necessary solidification zone are made larger. This was achieved by increasing the casting wheel diameter to 4.2 metres. A casting wheel of that size produces an aluminium bar with a cross-section of up to 5,500 mm2. A downstream rotary shear cuts the cast strand into bars, in other words ingots, with a reproducible length and a tolerance of ±0.5 percent. The capacity of the 4.2 m casting wheel is up to 20 tonnes per hour; considering ingots of 10 kg we are talking of 2,000 ingots per hour. No skimming is needed and the ingots are flat and smooth, with no cavities and no cracks. ALUMINIUM: That was already a big step forward, but did it achieve your development objective? Brocato: For the refiner market, at first it did. Raffmetal ordered two more ingot casting wheels at intervals of a few years. At the end of the 1990s the Italian company Sacal too installed two complete in-line casting lines equipped with an automatic stacking and strapping station. ALUMINIUM: How did the primary smelters rate your development? Brocato: From the beginning there was a lot of interest, with the result

that in 2005 Dubal, as art of its ‘Kestrel’ expansion project, began operating a high-performance casting plant for ingots supplied by ContinuusProperzi, which included the packaging equipment, in other words the stacker, weighing machine and the strapping and labelling equipment. The plant produces 10-kg ingots at a rate of 2,000 per hour for unalloyed aluminium and 1,500 per hour for alloys with a high silicon content. At the same time we supplied similar plant with comparable performance to Alba in Bahrain. ALUMINIUM: What happened next? Brocato: The quality advantages compared with conventionally produced ingots could not disguise the fact that the plant production performance attainable was largely determined by the casting wheel diameter. So to boost the output of the plant to over 2,000 ingots per hour, we would have had to increase the casting wheel diameter to more than 4.2 metres, which we did not regard as desirable for various reasons. ALUMINIUM: What alternatives did you have? Brocato: It made no sense to keep increasing the casting wheel diameter in order to adapt the length of the solidification zone to achieve the required capacity boost. Our considerations therefore led to the solution of choosing an ‘infinitely’ large casting radius but in doing this, keeping the size of the plant, namely its height, within reasonable limits (see the preceding article). ALUMINIUM: How has the Track &

Business Contact Successful for many years, aluminium sales team from southern Germany

seeks a new challenge. Our team has a very good knowledge of the southern German market and relationship with customers in European submarkets. Wanted is a business relationship to an extrusion plant. The establishment of a complete wholesale branch or a plant stock trading is conceivable. Please reply to box-number AL-1766 at Giesel Verlag GmbH, Rehkamp 3, D-30916 Isernhagen.

48

Belt system been received by the market so far? Brocato: The first unit began operating during the year 2005 at the company Carlo Vedani Metalli in Milan. This was followed by further units at Raffmetal and Raffineria Metalli Capra in Brescia, Raffmetal still prefers the light ingots of 8.5 kg. ALUMINIUM: How do you view the future of the new system, bearing in mind the smaller weight of the individual ingots? Brocato: The Track & Belt system is

View of Properzi bundles before strapping (one tonne approximately)

attracting a lot of interest, both in the field of aluminium recycling and from aluminium smelters. From the productivity standpoint we see that 30 lb (= 13.6 kg) ingots are gaining ground. Taking the quality advantages into account as well, which ultimately also translate into increased productivity, with the Track & Belt system for 30-lb ingots and a capacity of 28 tonnes per hour we are exactly at the point toward which the market is tending. With the data available in our records, and also taking advantage of the experience in the wire rod sector, where the equipment is much more complex and more maintenance demanding, we know that an overall efficiency of our equipment of 85 percent is a realistic data and the production expected for a line of 28 tph (30 lbs/13.6 kg ingots) is close to 170,000 tpy considering 300 working days a year. Last but not least, the idea of 30 lbs/13.6 kg originated by our chairman – Mr Giulio Properzi – finds his ground on the necessity of giving better working conditions to those users of ingots who, having small size furnaces, are obliged to handle singular ingots manually. ■

ALUMINIUM · 3/2010

co m pa n y n e w s w o r l d w i d e

aluminium smelting industry

The whole energy situation in Venezuela is dramatic. Any further cuts to Bauxilum output are a threat to the country’s whole aluminium industry.

Norsk Hydro

chinalco may build aluminium smelter in Gansu

alcoa and Bpa reach power supply accord for intalco smelter Alcoa and the Bonneville Power Administration (BPA) have reached an agreement to provide power for the Intalco aluminium smelter in Ferndale/Washington. The new contract provides Alcoa with up to 320 MW of power at the Industrial Power (IP) rate and will allow the plant to produce a total of 184,000 tpy. Alcoa is a 70-year customer of BPA and this contract marks a return to direct power sales under the Northwest Power Act. Direct power sales were halted in 2006. The new contract has two phases: an immediate 17-month power supply for up to 320 MW, and a second phase for at least an additional five years of power. The second phase would be implemented following clarification of a recent US 9th Circuit Court of Appeals ruling and will depend on the state of future power markets.

Venezuela cuts steel and aluminium output to save power Venezuela will chop output at its leading steel mill and at two aluminium smelters (Alcasa and Venalum) to reduce energy consumption by about 558 MW. The cuts are due to falling water levels at the Guri hydroelectric dam which supplies about 70% of the country’s electricity. At Alcasa, the government will shut two production lines permanently and will focus on

ALUMINIUM · 3/2010

increasing production at two other lines via investment. For the moment, this shutdown would cut production by about 1,600 tpm. The cutbacks would reduce consumption by about 58 MW at Alcasa and by about 300 MW at Venalum. The Venezuelan government will install thermoelectric plants to supply energy to the country’s stateowned primary aluminium producer CVG Venalum. Plants with capacity to generate 100 MW capacity will feed Venalum. Venalum has made further cuts to production by shutting another 33 electrolytic cells at its plant in addition to the initial 360 cells. Venalum’s output will fall by almost 50% in 2010 to around 220,000 tonnes if the cells remain idle. CVG Alcasa, also a state-owned company with capacity to produce 200,000 tpy, has closed more than 430 out of 680 cells. The Venezuelan government will cut the power supplied to state-owned bauxite and alumina producer CVG Bauxilum by 50% as part of its national power saving plan. The government told CVG Bauxilum to save half the energy it consumes, from 45 MW to 22.5 MW. Bauxilum would have to invest a further USD284m to produce 1.65m tonnes of alumina in 2010, and then to reach its installed capability of 2m tpy in the following years. But the company only produced 1.37m tonnes in 2009 and would not even reach an output of 1 million tonnes in 2010 if the 50% energy cut is implemented.

Aluminium Corp. of China (Chinalco) may build a smelter in Qingyang city, Gansu province, boosting capacity by more than 10%. Chinalco seeks to invest in alumina and aluminium capacity in energy- and resource-rich areas in China and overseas. The city government and Chinalco had signed a framework agreement to build a 500,000 tpy aluminium smelter and develop a coal mine. Details of the aluminium smelter project would be finalised in 2010. The Qingyang smelter project could be built and operated by Chalco. If built, the Qingyang smelter will be Chalco’s fourth smelting facility in the northwestern province. But getting central government approval may be a struggle, as Beijing looks to close 800,000 tpy of old smelting capacity by the end of 2010, and has said that in principle it will not approve any new smelters in 2009 to 2011 as the country already has more capacity than it needs. Chinalco would also develop a mine with proven reserves of 102m tonnes of coal, an essential material for energy-intensive aluminium production. Coal-rich Qingyang city has 10.4bn tonnes of proven coal reserves.

india’s nalco plans new refinery and smelter India’s state-run Nalco wants to set up mines and a refinery project in the southern Andhra Pradesh state and to add a second aluminium smelter in the eastern state of Orissa, according to the government. Nalco plans to spend 57bn rupees (USD1.2bn) in the Andhra Pradesh project and 163.5bn rupees (USD3.44bn) in Orissa for the smelter and for a captive power plant. The proposed aluminium smelter would have a capacity of 500,000 tpy and would be completed in two phases. ➝

49

co m pa n y n e w s w o r l d w i d e

At the end of December 2009, the expansion at Hindalco’s Muri refinery and Hirakud smelter in Orissa resulted in a 50% rise in alumina production at Muri and a 12% increase in metal production at Hirakud. The Hirakud smelter’s expansion to 155,000 tpy capacity from 143,000 tpy has been completed on time and work on expanding the smelter to 213,000 tpy from 155,000 tpy is under way. The initial capacity expansion phase to 161,000 tpy will be completed by July. Hindalco’s 1.5m tpy Utkal Alumina project at Rayagada, Orissa, is expected to be complete by July 2011. The company’s Aditya aluminium project in Orissa, which includes a 1.5m tpy alumina refinery, a 359,000 tpy aluminium smelter and a 900 MW captive power plant, is expected to come on stream by October 2011. The Mahan aluminium project, which is being built in the central Indian state of Madhya Pradesh, will start production by July 2011. Its 359,000 tpy capacity Jharkhand aluminium smelter project at Sonahatu in the eastern state of Jharkhand is still in the land acquisition stage. It is expected to come on stream by June 2013.

Bosnia’s aluminij mostar sees better 2010 after tough year Bosnia’s sole aluminium smelter expects an improved 2010, due to expanding demand and rising global prices, after posting a 30% decline in revenues and flat profit in 2009. The smelter produced 96,000 tonnes of primary aluminium in 2009, down from 123,000 tonnes in 2008, after cutting output by a quarter last year. The smelter gradually started returning to full production in autumn last year. It produces anodes, billets, wire, ingots, T-bars and slabs used in the metal, construction and car industries, which have been hard hit by the global economic crisis. Its full capacity is 135,000 tpy. Its revenues and exports fell by a third in 2009 to close to 138m Bosnian marka (USD103m) and 260m marka

50

respectively. The company had earlier said that its annual production could reach 300,000 tonnes if plans to build a plant for aluminium waste recycling and electrolysis went ahead. The plans can proceed only after the company has been privatised and has found a power supplier offering favourable electricity prices. The government of the MuslimCroat federation, an autonomous region that makes up Bosnia along with the Serb Republic, extended until May a deadline for the sell-off of an 88% stake in Aluminij Mostar – held half by the company and half by the government. This is the fourth extension since 2007; it was made to give more time to resolve some outstanding issues. The sale of Aluminij Mostar to the best bidder, a consortium led by Swiss-based commodities trader Glencore International, has been stalled over high electricity prices and environmental and ownership issues.

Vedanta resources phased out soderberg capacities in india Aluminium production at its Balco subsidiary fell 30% y-o-y during the quarter to 65,000 tonnes as the company shut its 100,000 tpy smelter to set up a new one with a capacity of 325,000 tpy. The new smelter is expected to be operational by the third quarter of the next financial year.

The company’s Vedanta Aluminium project in Orissa, in which it holds a 25% stake, was commissioned in November 2009 and has a capacity of 225,000 tpy. The second phase of the project with a similar capacity will be operational by March. Sterlite’s parent company, Vedanta Resources, holds the remaining 75% stake in Vedanta Aluminium.

nalco to hit expanded 460,000 tpy capacity in 2010 India’s National Aluminium Co. (Nalco) plans to reach its full expanded capacity of 460,000 tpy of aluminium in 2010. Nalco commissioned all 240 aluminium potlines in mid-December and plans to produce around 39,000 tpm for the year. Aluminium exports may also increase from just over 100,000 tpy. Arrangements are being made to import coal to build up stocks. Nalco has completed its expansion of bauxite mining capacity from 4.8m to 6.3m tpy but has yet to reach full production of alumina, because Maoist attacks delayed work on the refinery expansion. This expansion from 1.57m to 2.1m tpy is now expected to be finished by December 2010. The expanded power capacity from 960 MW to 1,200 MW will be fully operational when the last 120 MW power plant starts up in March.

■

Bauxite and alumina activities

Alunorte

Hindalco’s expansion projects make headway

windalco to lay off 762 employees UC Rusal will cut 762 more jobs at its

majority owned West Indies Alumina Co. (Windalco) in Jamaica. The layoffs will be completed by March and were

ALUMINIUM · 3/2010

co m pa n y n e w s w o r l d w i d e

demanded by the Refinery’s employees, who are being paid a three-day week but preferred to receive severance packages and to find work elsewhere. The decision to lay off most of its remaining work force comes nine months after Rusal suspended production at its Kirkvine and Ewarton refineries, along with output at Alumina Partners of Jamaica (Apart), under the weight of sluggish alumina demand.

Market impact is, however, expected to be limited as inventories are high and alumina prices are expected to fall as a result of weak buying. Nanchuan Alumina mainly supplies to 110,000 tpy Aba Aluminium in Sichuan province, and both are whollyowned subsidies of private company Bosai Group. Aba Aluminium has also felt the power supply tightness but is willing

to pay a price to maintain production. Both Nanchuan Alumina and Aba Aluminium plan to expand in 2010. Nanchuan Alumina plans to boost alumina capacity by 150% to 500,000 tpy by May or June, while Aba Aluminum plans to start commissioning 90,000 tpy of new capacity at the end of May. Most of Aba Aluminium’s expanded alumina needs will be supplied by Nanchuan Alumina. ■

recycling and secondary smelting China’s Yankuang Corp. has taken an 8.42% stake in Bauxite Resources for 9.85m Australian dollars (USD9m), following approval from Australia’s Foreign Investment Review Board (FIRB). FIRB also approved the companies 50 : 50 bauxite-to-alumina joint venture that aims to generate 150 to 300m tonnes of refinery grade bauxite. In October 2009, Yankuang took over 100% of major Australia coal producer Felix Resources through its Australian subsidiary Yancoal Australia. Yankuang, based in eastern Shandong province, produces mainly coal and more than 140,000 tpy of aluminium.

Hydro

yankuang takes 8% stake in Bauxite resources

India’s JSW Aluminium secured 4.2m tpy of bauxite from the Andhra Pradesh state government for a proposed 1.2m tpy alumina refinery. The bauxite price will be based on the LME price and equipment orders will be placed from April for the Rs45bn (USD973m) alumina refinery in Viziayanagram district. Only state companies can mine bauxite in Andhra Pradesh so JSW’s supply will come from Andhra Pradesh State Mineral Corp.

Two recycling smelters in Mount Pleasant, Tennessee, have failed to convince the City’s Planning Commission to rezone a 90 acre parcel for disposal of salt cake and baghouse material. Local disposal would cut costs and allow for the possibility of salt cake recycling as technology develops. Tennessee Aluminum Processors and Smelter Service Corporation will continue to have access to the state-approved disposal facilities they now use. An earlier landfill for smelter waste existed nearby but was shut down in the mid-1990s.

ium remelt plant in Taiwan with a capacity of 75,000 tpy of extrusion ingot. Taiwan is the third-largest extrusion market in Asia, with a total extrusion ingot consumption of about 400,000 tonnes. The remaining ownership of the Famco aluminium remelt plant will continue to be held by the holding company E-Tech, in which Lawrence Cho is the main shareholder. Famco is located in the Yunlin Industrial Estate in Yunlin County, along Taiwan’s western coast. The plants equipment allows for efficient production of a wide product range, including diameters ranging from four to nine inches, as well as special alloys.

nanchuan alumina cuts output by a third

Hydro increases ownership in Taiwan remelt plant

Kaye presteigne goes into receivership

China’s Nanchuan Alumina Refinery in southwestern Chongqing city is operating at two-thirds of its 200,000 tpy capacity due to insufficient power.

Hydro has signed an agreement to increase its ownership stake in Famco from currently 45% to a controlling majority stake. Famco is an alumin-

UK aluminium diecaster Kaye Engineering, which trades as Kaye Presteigne, goes into receivership. Brian Johnson and David Birne of Fish- ➝

Jsw secures bauxite for 1.2m tpy alumina project

ALUMINIUM · 3/2010

aluminium smelters rebuffed on salt cake landfill in Tennessee

51

co m pa n y n e w s w o r l d w i d e

er Partners in London were appointed to administrators. Kaye Presteigne, like other diecasters in the country, has been under pressure from a lack of credit insurance and raw material price volatility. Lack of credit insurance and financing have weighed heavily on the secondary aluminium sector since the global recession hit. Diecasters, which traditionally buy their aluminium alloy on longterm contracts, have struggled to pass on the dramatic rises in raw material costs since demand returned. LM24 diecasting ingot rose to trade at £1,280-1,330 (USD2,083-2,165) per tonne in mid-January, its highest level since October 2008. This represents an increase of almost 70% since February 2009 when LM24 was trading at USD790-900 per tonne. As a result, several diecasters have to pay more

for their aluminium alloy than their customers have agreed to pay for their end product. Kaye Presteigne, based in Powys, Wales, was formed in 2006, when its US parent company JL French filed for Chapter 11 bankruptcy protection and the administrators sold off the business. Its high-pressure foundry operates 16 machines, with capacities ranging from 200 tonnes to 750 tonnes, and produces castings ranging in weight from 5 grams to 5 kg. In addition, the gravity-casting facility includes a fully-automated in-line gravity plant, capable of producing more than 1m castings a year. Peter Neagle, Paul Davidson and Geoffrey Smith are listed as Kaye Engineering directors, and solicitor John Bailey as company secretary.

■

aluminium semis

its Warrick operations in Newburgh/ Indiana, before the end of the first quarter. The cuts represent a nearly 10% staffing reduction for the 1,000 employee division in Tennessee. The staffing reductions are the result of reduced can sheet demand in 2010. Alcoa is working with union leaders to offer early retirement packages to reduce the number of involuntary layoffs that will have to take place.

sapa installs extrusion press at cressona facility Sapa Holding and the United Steelworkers union have signed a new collective bargaining contract for about 600 hourly employees at the Sapa Extrusions plant in Cressona/Pennsylvania. The contract, which will run through November 2013, includes wage increases in each year and a restructured health benefits package. Sapa Extrusions operates five plants in Cressona, Connersville, Elkhart and Kokomo, all located in Indiana, and Spanish Fork/Utah. The Cressona operation is installing a 3,600tonne direct-extrusion press that can extrude 254 mm billets to produce profiles with up to a 254 mm circle size. The installation costs about USD4m, with start-up projected for the third quarter of 2010.

soUTH america

Alba

cabelum’s aluminium supply down 70%

norTH america

is a wholly owned subsidiary of global miner Rio Tinto.

alcan cable to shed more jobs Alcan Cable will lay off 33 employees from its Roseburg/Oregon facility in response to a difficult market environment. The layoffs are part of the Worker Notification and Retraining Notification (WARN) Act and are the second round for the facility. In April 2009, the company had already announced 32 layoffs at the same plant. Alcan Cable, based in Atlanta,

52

alcoa to lay off staff from can sheet plants Alcoa will lay off some 235 employees from the Rigid Packaging division in the first quarter in response to lowerthan-anticipated sales projections for the year. The company will slash some 90 jobs at the Tennessee operations near Knoxville and 145 jobs at

The aluminium supply at Venezuelan cable producer Cabelum has dropped some 70% because of two production lines that were shut down at aluminium smelter Alcasa and the 360 cells that were stopped at aluminium smelter Venalum. Under normal conditions the company receives 1,800 tpm of aluminium and now this has fallen to around 600 tpm. The government’s goal is to provide each transforming company with only the aluminium needed to operate at minimum capacity. Cabelum has installed capacity to transform 2,000 tpm of aluminium.

ALUMINIUM · 3/2010

co m pa n y n e w s w o r l d w i d e

In November 2009, Cabelum started the second phase of an expansion project worth USD11.6m which includes the installation of drawn wire and cabling machinery that will increase production to 30,000 tpy. With the increased production, the company could start exporting to markets like Chile, Brazil and Bolivia. Cabelum, Alcasa and Venalum are all state controlled.

alcoa recognised by Honda for quality Alcoa Latin America’s Utinga plant in Santo André, Brazil, was recognised by Honda Motorcycle of Brazil for outstanding quality performance. Alcoa received Honda’s top quality supplier award following Honda’s thorough assessment of its supplier network in Latin America over a 12month period. Alcoa is the exclusive supplier of extruded aluminium tubes for the rear suspension of several of Honda’s popular motorcycles for the Latin American market. By using Alcoa’s lighter, high-strength 7xxx series aluminium alloy in the suspension system, Honda improved the motorcycle’s performance significantly by reducing the weight of the swing arm, meeting customer’s expectation. The Utinga plant supplies extrusions to a number of Latin American market segments, including the ground transportation, industrial machinery and electrical equipment markets.

alucasa output expected to drop Output at Venezuelan state aluminium products company Aluminios

Carabobo (Alucasa) could drop by 40% because of the production lines that were shut down at the aluminium smelter. Alcasa is Alucasa’s main raw materials supplier, and now that two of its production lines have been closed it will not be able to provide the needed aluminium. The closure significantly lowers the 1,000 tpm of aluminium that Alucasa had been receiving. Now only about 600 tonnes will come in, which will seriously reduce production levels. Both Alucasa and Alcasa are controlled by state heavy industry holding company CVG. The Alucasa plant has installed capacity of 23,000 tpy and as of October was producing at a rate of only 8,400 tpy. In December, the Venezuelan basic industry and mining ministry (Mibam) lowered the power supply available at state industry plants in the Guayana region, so that Alcasa had to shut down production lines 1 and 2 as part of the procedure. In November and December, Alucasa produced 1,300 tonnes of thin sheet aluminium products. In October, Alucasa was operating at less than 40% of its capacity due to a lack of investments in technology, and workers petitioned the government to provide a rescue plan in order to avoid a deeper crisis and subsequent closing. Meanwhile, the Venezuelan government has promised to contribute USD150m to start the first stage of installing a new fabrication line at state aluminium smelter Alcasa. The government has also guaranteed that all workers from production lines 1 and 2 will still have jobs and has promised to pay all benefits. The workers were left unemployed when production lines 1 and 2 closed down, and are studying the possibility of dismantling these lines and installing a new plant.

We purchase and supply: n Rolling mills cold/hot n Roll grinding machines n Continuous casters n Levellers/straighteners n Drawing machines

n Slitting lines n Cut-to-length lines n Coilers n Coil carriages n Rollformers

n Tube welding machines n Extrusion presses n Joining presses n Packing lines for strips

Please ask for our sales list! COILTEC Maschinenvertriebs GmbH · Silberkaute 4 · 57258 Freudenberg Phone +49 (0) 2734/271190 · Fax +49 (0) 2734/271195 www.coiltec.de · email: [email protected]

ALUMINIUM · 3/2010

There are two proposals on how to go about the transformation process, one for rolling and the other for extruding, for which Alcasa already has the resources needed.

eUrope armenal produces over 20,000 tpy of thin foil for first time in history UC Rusal announced that, for the first time since its commissioning, the Armenal plant produced and sold over 20,000 tpy of aluminium foil, nearly twice as much as in 2008. In 2009, the mill significantly improved labour efficiency and almost doubled its productivity rate per employee. Armenal’s yield ratio, currently exceeding 70%, stabilised, and the rate of production rejects fell to 3%, which is also the best figure ever achieved by the foil mill. Since January 2009, Armenal has fulfilled nearly 1,500 export orders and launched full-scale production of ultra-thin foil, which is designed for further gauging. Having improved the quality of foil roll cutting by upgrading the cutting plant, the foil mill has started to produce narrow-width 40 to 50 mm foil, which is in high demand in the global markets.

Hydro’s divestment of spanish rolling mill completed The sale of Hydro’s rolled products Inasa plant in Irurtzun, Spain, was finalised at the end of December 2009. The plant near Pamplona is now operated by Bavaria Industriekapital AG under the name Inasa Foil SA. As announced in December, the transaction is cash-neutral for Hydro, which will record an after-tax book loss of about NOK200m (USD35m) in its fourth-quarter 2009 results. The plant, with more than 200 employees and a capacity of 30,000 tpy, had been part of Hydro’s Rolled Products business, which remains a leading, worldwide supplier of rolled aluminium products, shipping up to ➝

53

co m pa n y n e w s w o r l d w i d e

1m tpy and employing a workforce of around 4,000. Hydro will continue serving Spanish customers of rolled aluminium products through its sales office in Barcelona.

Hydro selling Hydro Trans to sKa invest Norwegian investment company SKA Invest has entered into an agreement to buy Hydro Trans, which has activities in Norway, Finland and Denmark. Hydro Trans is a Nordic supplier of aluminium systems for heavy transport. The company, wholly owned by Hydro, has 20 employees at production sites in Norway and Denmark, and a sales office in Finland. In 2009, Hydro Trans delivered 650 tonnes of aluminium-based systems. It has a market share of about 20%. SKA Invest has earlier acquired other businesses from Hydro, namely Hydal and Extrusions Tools. Both have experienced good development. The transaction, to be completed 1 March, is dependent upon approval by competition authorities.

alcan packaging sale finalised Rio Tinto announced that it completed the sale of the Alcan Packag-

The author The author, Dipl.-Ing. R. P. Pawlek, is founder of TS+C, Technical Info Services and Consulting, Sierre (Switzerland), a new service for the primary aluminium industry. He is also the publisher of the standard works Alumina Refineries and Producers of the World and Primary Aluminium Smelters and Producers of the World. These reference works are continually updated and contain useful technical and economic information on all alumina refineries and primary aluminium smelters of the world. They are available as loose-leaf files and/or CD-ROMs from the Aluminium-Verlag, Marketing & Kommunikation GmbH in Düsseldorf, Germany.

54

ing global pharmaceuticals, global tobacco, food Europe and food Asia divisions to Amcor for a total consideration of USD1.95bn. In August 2009, Rio Tinto announced the receipt of a binding offer from Amcor for these businesses for a total consideration of USD2.03bn. The transaction has clearance from the European Commission and awaits clearance from the Department of Justice in the US. The completion of this complex transaction is another significant step in the recapitalisation of Rio’s balance sheet. Since the start of 2009 Rio completed divestments of USD5.6bn despite a difficult environment created by the global economic crisis. Since February 2008, Rio has announced asset sales of USD10.3bn. ■

supplier aBB successfully commissioned rectifier stations at Qatalum Twenty-eight months after the 140m US-dollar contract between Qatalum and ABB was signed, power and automation technology group ABB success-

fully commissioned ten complete rectifier units at Qatalum’s primary aluminium plant. Handover of the plant to the customer took place in midDecember 2009. ABB acted as EPC contractor for the rectifier stations and was responsible for engineering, civil design, material delivery, training, documentation, installation and commissioning. The scope of supply included ten high voltage rectifier units (each 1650 V, 85 kA) including control and protection systems, two DC collector busbar systems (each 340 kA) including ABB’s fibre optic current sensor (FOCS), ten regulating and rectifier transformers including reactive power and harmonic filtering systems, two SCADA systems (Supervisory Control And Data Acquisition), as well as redundant auxiliary systems (transformers, low voltage distribution, motor control centres, battery systems, uninterruptible power supply, fire alarm and extinction systems, air-conditioning). ABB also delivered and installed 47 kilometres of high voltage cables (220 kV) to connect the rectifier stations to the dedicated 1,250 MW power plant.

■

on the move Alcoa appointed Nicholas Ashooh vice president, Corporate Affairs. He will be a member of the Alcoa Executive Council and have oversight for global communications, government affairs, community relations and the Alcoa Foundation. Mr Ashooh succeeds John D. Bergen, who has been appointed vice president, Human Resources. UC Rusal announced a management reshuffle in its aluminium division: Eugueny Zhukov, who previously held the position of managing director of the Krasnoyarsk smelter (KrAZ), was appointed general director of the Urals aluminium smelter (UAZ). Mr Zhukov will be replaced by Eugueny Nikitin, the former managing director of the Sayanogorsk smelter (SAZ). Meanwhile, Boris Smolyanitsky, who had been managing UAZ for nine years, was appointed adviser to lead the aluminium division. Anton Savchenko, who had been the financial director of the Sayanogorsk

smelter since 2006 after joining the smelter in 1996, will be acting managing director of SAZ. Jean-Marc Noe, director of alumina sales at Rusal, has left the Russian aluminium producer. Alexei Gordymov will take over as a commercial director of the alumina division. Alba’s manager (Infrastructure and Engineering) Ahmed Mohammed Al Hashimi has been appointed chairman of the Bahrain Occupational Standards Review Committee. Alba’s Public Relations manager, Khalid Jassim Bomtaia, has left the company. Alba’s Human Resources manager, Abdulrahman Janahi, takes over the Public Relations department as acting manager till further notice. The BHP Billiton board announced the retirement of Paul Anderson and Gail de Planque from the board. Mr Malcolm Broomhead and Ms Carolyn Hewson have been appointed as non-executive directors.

ALUMINIUM · 3/2010

research

Innovative joining methods for lightweight designs, Part II* Michael Marré 1, Christian Weddeling 1, Thilo Hammers 2, Matthias Merzkirch 2, Jens Rautenberg 3, Prof. Dr.-Ing. Erman Tekkaya 1, Prof. Dr.-Ing. Volker Schulze 2, Prof. Dr.-Ing. Dirk Biermann 3, Dr.-Ing. Dipl.-Inform. Andreas Zabel 3

Methods and procedures: The complexity of the lightweight nodes and their requirements of geometric accuracy and surface quality need precise process planning and adequate machining set-up for manufacturing. Multi-axis machining set-ups provide a high flexibility in development and realisation. They allow milling, drilling, threading and reaming of the nodes from five sides, depending on the machining system being used. The decrease in the number of changes to the clamping set-up avoids interactive defects and geometric inaccuracies and therefore increases the economic efficiency of the process. From a given CAD model of the frame structure with all the necessary elements, the models of the nodes can be used for further planning (Fig. 1). The CAM system, as used for the manufacturing of complex parts like dies and moulds, allows the generation of machine specific NC data, depending on which element or surface should be manufactured and which tools and cutting parameters should be used. A Deckel-Maho 5-axis milling and machining centre (DMU 50 Evolution) was chosen to manufacture the lightweight node and its integrated structured surfaces. There are two basic ways to structure the surface of a joining zone. The micro structure can be described by characteristic surface parameters, e. g. average surface roughness, core roughness depth, or the contact area percentage. This is important for a tight fit between the inner and the outer specimen [20]. Macrostructures can be seen as pockets, grooves and nuts, which allow the profile to fit into * Part I of this paper, focusing on friction stir welding and bifocal hybrid laser welding, was published in ALUMINIUM 1-2/2010.

ALUMINIUM ·3/2010

Images: IUL / iwk I

Joining by hydroforming and electromagnetic expansion

Fig. 1: Process chain for joining of frame structures

or onto the node to obtain a form-fit. The transition between both types of surface characteristics is smooth, with the definition within this article being that macro structures have a visible depth (> 50 μm) and micro structures are only measurable (< 50 μm) but not visible. The micro structured surfaces lead to a more interference-fit-based connection due to the influence of the friction and tangential stresses between both joined elements. Macrostructured surfaces allow a form-fit joint.

It must be taken into account, however, that the degree of deformation depends on both the material characteristics and the shape (depth, width, length) of the formed element. For the purpose of process-safe, economic, and flexible milling, coated standard ball end mills aluminium were chosen to mill the aluminium. Helical tool paths for the simultaneous five-axis finishing strategies help to keep constant engagement conditions between tool and work piece in order to produce a homogeneous, constant ➝

Fig. 2: Process of joining by dieless hydroforming

55

research

surface quality, to avoid collisions between the tool and the tool holder and to reduce the risk of long, oscillating tools [Wei05]. After production has taken place, one of the forming processes can be used to assemble the frame components. Dieless hydroforming: The process of joining by dieless hydroforming can be divided into three characteristic phases, which are indicated in Fig. 2. In the first phase, the tube will be expanded to some value within the clearance (gap a0) limit. After that, both parts (tube and hub) are expanded together until a maximal radial displacement is reached, which is determined by a related joining pressure. The pressure ideally creates elastic and plastic deformation in the tube but solely elastic deformation in the hub. Consequently, Kollmann [21] suggests that for the manufacturing of shrinkage fits a maximum plastic deformation of approximately 30% should be attained, relative to the total cross section of the joining partner. After releasing the pressure, both tube and hub recover elastically. Subsequently, the elastic recovery of the hub is prevented due to the plastic deformation remaining in the expanded tube. Furthermore, the prevented elastic recovery of the hub results in an interference fit between the joining partners (tube and hub). It is known from the manufacturing of camshafts that if both joint partners possess the same Young’s modulus then the joining partners should be arranged

with increasing yield points from the inner to the outer joining partner [22]. Joining of aluminium and magnesium, as well as the influence of maximum expansion under pressure, wall thickness of the hub, and initial gap on the strength of the joint, have been briefly presented in [23]. More detailed discussions take tools and repeatability into account [24]. From an engineering standpoint, the working parameter of the fluid pressure pf represents an important value for estimating the resulting strength of the joint. According to research work performed by Garzke [22], the interference pressure p, which is the stress in the contact area of the tube and hub, can be calculated using an approximation. Electromagnetic expansion: Electromagnetic forming (EMF) is a noncontact high velocity process using pulsed magnetic fields to deform materials with high electrical conductivity, such as copper and aluminium alloys. Depending on arrangement and geometry of the tool coil and the work piece, EMF can be used for sheet metal forming operations or for compression or expansion of hollow profiles [25]. Fig. 3 shows the typical set-up of work piece, tool coil and forming machine for the electromagnetic expansion of a square tube. This set-up can be represented by a resonance circuit in the equivalent circuit diagram. Within this diagram the forming machine is symbolised by the capacitance C, the inner resistance Ri and the inner inductance Li. The work

Fig. 3: Principle of the production of a square tube-to-hub joint by electromagnetic expansion

56

piece and the tool coil can be seen as the consumer load. Due to a sudden discharge of electricity from the capacitor, a damped sinusoidal current I(t) runs through the coil. This current, which typically ranges from 10 to 1,000 kA, generates a magnetic field H(r,z,t) around the coil within several microseconds. According to Lenz’s law, this magnetic field induces eddy currents in the work piece which are in the opposite direction of the coil current, and shield the magnetic field. The energy density of the magnetic field represents a pressure p(z,t) acting orthogonally on the workpiece [25]. Plastic deformation of the tube will occur once the stresses in the work piece due to this pressure exceed the yield stress of the material. A currently well investigated application of EMF in research is the forming of sheet metal where the work piece can either be deformed freely or into a die to create a defined shape. The process can also be used to calibrate work pieces which were preformed by a conventional quasi-static process [26] or for cutting/shearing operations, but the most commonly used industrial application of EMF is the joining of closed hollow profiles. By using electromagnetic compression or expansion it is possible to produce dominating interference-fit joints or dominating form-fit joints [27]. In the case of very high impact velocities of the electromagnetically driven part it is possible to produce adhesive bonds between the joining partners. This application is called magnetic pulse welding [28]. The strength of the interference-fit depends on the area of the contact zone, the friction coefficient and the residual interference stresses in the contact zone. The interference stresses are influenced by the material properties of the joining partners, such as yield stress and Young’s modulus. The geometrical stiffness of the part to be joined also affects the interference stresses [29]. According to [30] and [31] the strength of interference-fit joint produced by electromagnetic compression depends on the geometry and the shape of the groove as well as on the number of grooves. Both authors

ALUMINIUM · 3/2010

research

used cylindrical specimens for their analyses. analysis of joint characteristics Strength of hydroformed joints: The strength of the joint against an axial load is mostlydependent on the area of contact Acon, the interference pressure p, and the friction coefficient μ between the two joining partners, as indicated in equation (1)

Fax = Acon . µ . p

(1)

a wall thickness of 5 mm. Taking the results of preliminary investigations [33] into account an acceptable tangential strain of approximately 1.5% was detected, and the gap a0 was set to 0 mm. The pressure in phase 2 was adjusted to 74 MPa, resulting in an expansion of 0.4 mm. After joining, an axial load was applied using a tensile test machine, and the results are displayed in Fig. 4. At first, an increase of the average surface roughness led to an increase of the axial load. Tubes with a knurled surface were significantly less resistant to deformation during tensile tests compared to specimens with a milled surface. As a result, the peaks created by knurling the tube surface were too large to generate an appropriate undercut with the opposite surface of the hub. Moreover, a penetration of the roughness peaks into the opposite surface did not occur as the pressure had already led to the maximum expansion. Using a die, an increase of fluid pressure could lead to the mentioned penetration. Consequently, as only the tips of knurling were in contact to the inner surface of the hub, the area of contact was significantly smaller compared to the machined specimens. Since the area of contact is directly proportional to the axial load, the reduction in maximum axial load is clearly evident. Joining of square reinforced aluminium profiles by electromagnetic expansion: Previous analysis regarding the strength of form-fit joints considered primarily tubular specimens deformed by electromagnetic compression [30, 31]. This work is a first experimental approach to extend these analyses of form-fit joints towards reinforced square tubes

produced by electromagnetic expansion. To generate the form-fit joints a specified area of the tube was expanded into the grooves of the outer joining partner, the hub (see Fig. 3). The square tool coil used within these experiments has an edge length of 40 mm and a length of 30 mm with 8 turns (E-40sqr-8/30). For this first approach the groove width wg and the groove length lg were kept constant. For wg a value of 20 mm was chosen, which equals four times the wall thickness of the profiles. For the magnitude of lg the inner diameter of the tubes was chosen (40 mm). The height of the buckles h was varied by changing the acting magnetic pressure and the charging energy E of the capacitor bank. The maximum height of the buckles was restricted by the beginning of debonding at the interface between the reinforcement wire and aluminium matrix. During the expansion of the tube the reinforcement wires are elongated. Due to volume constancy an increasing elongation leads to a decrease of the cross section and, therefore, to a separation of matrix material and wires [29]. Debonding at the interface disables or reduces load transmission between matrix and wire, and therefore is not acceptable. To determine the maximum allowable deformation and the corresponding charging energy for the joining, a preliminary test series was performed whereby the profiles were expanded with different charging energies within a defined area and restricted by solid collars. The distance between collars was equivalent to the groove width wg. The set-up of the preliminary experiments is shown in Fig. 5. After the deformation the heights ➝

The area of contact Acon depends on the length of the joint lj as well as the interference diameter, and is directly proportional to the resulting axial load Fax. However, the interference pressure depends on the inner and outer diameter of joining partners, material characteristics as yield stress, Young’s modulus, and Poisson‘s ratio, and the maximum fluid pressure during joining. Joining of two tubes made from the same material results in a low maximum axial load [27]. As a result, for an appropriate axial load to be achieved, a modification of the coefficient of friction seems reasonable. Therefore, adequate manufacturing strategies, developed by the ISF, to specifically adjust the roughness of the tube have been applied and its results on the strength of the joint have been investigated. In addition to the surface finishing by machining, burnishing was also applied as a forming process for surface finishing. The mean roughnesses achieved by the mentioned processes were Ra = 0,63 μm by burnishing, Ra = 3,4 μm to Ra = 7,5 μm by milling [32] and Ra = 10 μm by turning. To generate a disproportionately high roughness a knurl pattern was applied to the surface by a milling process, so that a calculated roughness of Ra = 250 μm as found. Tubes prepared so far were made from aluminium EN AW-6060, with an outer diameter of 40 mm and a wall thickness of 2 mm. They were joined with ring-shaped hubs that had an outer diameter of 50 mm and Fig. 4: Axial load depending on the surface finish of joints made by dieless hydroforming

ALUMINIUM ·3/2010

57

research

Fig. 5: Top: Set-up and results of the preliminary tests for the expansion of reinforced square tubes; bottom: Micrographs of the expanded tubes parallel to the wire

of the resulting buckles were measured with a coordinate-measuring machine. The results show that an increase in charging energy leads to an increase in deformation. In order to evaluate the quality of the bonding between the aluminium matrix and the reinforcement elements, micrographs of the electromagnetically formed specimens were prepared, which also clearly show the increasing deformation of the tube with increasing charging energy. Charging energies of up to 1.6 kJ did not result in debonding at the interface between the matrix material and the wire. A further increase of the charging energy led to debonding at the interface, marked with arrows in Fig. 5. Based on these preliminary tests, a maximum charging energy of 1.8 kJ was chosen for the joining experiments. Although a very little amount of debonding was observed at this energy, it was assumed to have no influence on the material strength. To separate the influence of a pure form-fit from the strength of the joint, all specimens were lubricated with Teflon grease before joining. As a result, the friction coefficient between the joining partners was lowered to a

58

negligible level. Therefore, it was possible to nearly prevent an additional interference-fit in the areas surrounding the grooves. After preparation the specimens were expanded into the grooves of the hub. Charging energies of 1.2 kJ, 1.4 kJ and 1.8 kJ were used. Afterwards, pullout tests of the joints were conducted using a universal tensile testing machine. The experimental results are shown in Fig. 6. The diagram of the pullout force F with respect to E indicates that a higher charging energy and the resulting larger height of the buckles lead to a higher strength of the joint. It can also be seen that the strength of the almost pure form-fit is very low compared to the material strength. This can be explained by the small ratio of the tube deformations compared to its wall thickness, due to the debonding restriction. conclusion / Discussion The necessity of a dedicated structuring of the surface of a joining zone is undeniable. The use of simultaneous five-axis milling strategies allow a reproducible structuring of the surface of lightweight connecting elements in

order to control and increase tensile and torsional strength of a joint. Interference-fit joining by expansion of joining partners made from equal material results in a weak interference pressure. As a result, the strength of the joint determined by the area of contact, interference pressure and the coefficient of friction can be increased by modifying the surface structure. Consequently, experimental investigations conducted so far have confirmed the possibility of increasing the strength of the joint by increasing the average surface roughness. However, there is a limit to the increase in strength which can be achieved by increasing the roughness. The joining experiments of reinforced square aluminium tubes by electromagnetic forming showed that an increase in the height of the buckles leads to an increase in the strength of the joint. It was also shown that the resulting joint strength was low within these tests due to the small allowable deformation. To achieve reasonable strengths of the joints, a combination of an interference-fit and form-fit would be better. Also, an optimisation of the form-fit might be helpful to increase the transferable load. In the case of non-reinforced tubes it can be assumed that significantly higher joint strengths can be achieved, since larger deformations are feasible. Hence, the knowledge of the interrelation between specific surfaces and the resulting effects on the quality of the joint allows the configuration of a flexible process chain for machining and joining lightweight frame structures. conclusions The presented innovative joining methods allow for flexible manufacturing of lightweight frame structures in limited-lot production. They enable an economic production process and lead to a lower structure weight. Experiments show the weldability of steel reinforced aluminium profiles by using friction stir welding. This method is able to join the aluminium matrix material, but does not connect the reinforcing elements. The pre-treatment (sawing, milling) of the

ALUMINIUM · 3/2010

research

Joining by Compression and Expansion of (Non-) Reinforced Profiles – In: Flexible Manufacture of Lightweight Frame Structures - Phase II: Integration, Weinert, K. et al. (eds.), TTP Trans Tech Publications Ltd, Switzerland, Advanced Materials Research (2008) Vol. 43, ISBN 0-87849-385-9, pp. 57-68 [30]Golovashchenko, S.: “Methodology of Design of Pulsed Electromagnetic Joining of Tubes”, Proceedings of the TMS Symposium “Innovations in Processing and Manufacturing of Sheet Materials”, 11-15 February 2001, New Orleans, Louisiana, pp. 283-299

Fig. 6: Results of the pullout tests of square reinforced tubes joined to square hubs

specimen has no significant influence on the joint strength. The aluminium alloy EN AW-6060, which is nearly impossible to fusion weld, can be joined by using bifocal hybrid laser welding. It could be shown that tube-tube-Ijoints can be produced with 93% of the tensile strength of the tubes by using an end crater reduction strategy. For modern joining by forming processes an undeniable necessity for dedicated structuring of the surface of the joining zone exist. The knowledge of the interrelation between specific surfaces and the resulting effects on the quality of the joint allows for the configuration of a flexible process chain for machining and joining lightweight frame structures. acknowledgement This paper is based on investigations of the Transregional Collaborative Research Centre SFB/TR10, which is kindly supported by the German Research Foundation (DFG). references References from [1] to [19] are listed in Part I of this paper, see ALUMINIUM 12/2010. [20] Hammers, T.; Marré, M.; Rautenberg, J.; Barreiro, P.; Schulze, V.; Löhe, D.; Brosius, A.; Tekkaya, E.: Influence of mandrel’s surface on the mechanical properties of joints produced by electromagnetic compression. In: ICHSF 2008 – 3rd International Conference on High Speed Forming, 11/12 March 2008, Dortmund, Germany, Proceedings, pp. 245-256, ISBN

ALUMINIUM ·3/2010

3-9809535-3-X [21] Kollmann, F.: Welle-Nabe-Verbindungen, Gestaltung, Auslegung, Auswahl, Springer Verlag Berlin (1984) [22] Garzke, M.: Auslegung innenhochdruckgefügter Pressverbindungen unter Drehmomentbelastung. Dr-Ing. Thesis. TU Clausthal, VDI Verlag Düsseldorf, 2001 [23] Homberg, W.; Marré, M.; Beerwald, C.; Kleiner, M.: Joining by forming of lightweight frame structures, In: Advanced Materials Research: Flexible Manufacture of Lightweight Frame Structures, Band 10 (2006), pp. 89-100 [24] Przybylski, W.; Wojciechowski, J.; Marré, M.; Kleiner, M.: Influence of design characteristics and manufacturing process parameters on the strength of tubular aluminium joints produced by hydroforming. In: Archives of Mechanical Technology and Automation, Vol.27 Nr. 1, Polish Academy of Science, 2007, pp. 152-167 ISSN 1233-9709 [25] Bruno, E. J.: High Velocity Forming of Metals. Dearborn, Michigan: ASTME, 1968 [26] Psyk, V.; Beerwald, C.; Henselek, A.; Homberg, W.; Brosius, A.; Kleiner, M.: Integration of Electromagnetic Calibration into the Deep Drawing Process of an Industrial Demonstrator Part. In: Key Engineering Materials Vol. 344 (2007), pp. 435-442 [27] Marré, M.; Ruhstorfer, M.; Tekkaya, A. E.; Zaeh; M. F.: Manufacturing of Lightweight Frame Structures by Innovative Joining by Forming Processes. In: International Journal of Material Forming, 2009 – accepted [28] Shribman, V.: Magnetic Pulse Welding for Dissimilar and Similar Materials. In: ICHSF 2008 – 3rd International Conference on High Speed Forming, 11/12 March 2008, Dortmund, Germany, Proceedings, pp. 245 -256, ISBN 3-9809535-3-X [29] Marré, M.; Brosius, A.; Tekkaya, A. E.:

[31]Bühler, H.; v. Finkenstein, E.: Bemessung von Sickenverbindungen für ein Fügen durch Magnetumformung. In: Werkstatt und Betrieb Vol. 104 (1971), pp. 45-51 [32]Biermann, D.; Weinert, K.; Zabel, A.; Engbert, T.; Rautenberg, J.: Machining of Lightweight Frame Components. In: Flexible Manufacture of Lightweight Frame Structures – Phase II: Integration, Weinert, K. et al. (eds.), TTP Trans Tech Publications Ltd, Switzerland, Advanced Materials Research (2008) Vol. 43, ISBN 0-87849385-9, pp. 37-46 [33] Hammers, T.; Marré, M.; Rautenberg, J.; Barreiro, P.; Schulze, V.; Biermann, D.; Brosius A.; Tekkaya, A. E.: Influence of Mandrel’s Surface and Material on the Mechanical Properties of Joints Produced by Electromagnetic Compression. steel research int., May Vol. 80 (2009) No. 5, S. 366-375; DOI: 10.2374/SRI08SP151

appendix 1

Technische Universität Dortmund

2

iwk I, Universität Karlsruhe (TH)

3

Technische Universität Dortmund

For subscribers www.alu-epaper.de even faster – your added PLUs to the print medium

59

Neue Bücher

Aluminium Lieferverzeichnis 2010 Das aktuelle Aluminium Lieferverzeichnis 2010 ist neu erschienen und ab sofort im Handel erhältlich. Das bewährte Nachschlagewerk der Aluminiumbranche und deren Zuliefererund Kundenindustrien enthält auch in diesem Jahr zahlreiche Informationen zu Unternehmen, Produkten und Dienstleistungen.

Im Lieferverzeichnis aufgeführt sind tausende Firmen der aluminiumerzeugenden und -verarbeitenden Industrien, der Zuliefererbranche, des Metallhandels und der Dienstleistungsanbieter. Die Unternehmen präsentieren ihre Produkte und Angebote von der Erzeugung über die Ausrüstung bis zur Anwendung. Technische Marktinformation, umfassende Händlernachweise und die Adressen von Prüfinstituten, Gutach-

Patentblatt Dezember 2009

tern und Dienstleistungsanbietern runden das Verzeichnis ab. Ergänzt wird diese Ausgabe durch den zweiten Teil mit technischen Fachausdrücken aus dem Bereich Strangpressen. Alphabetisch geordnet von M-Z sind die Begriffe aus dem „Glossary of Technical Terms – Extrusion of Metals“ in den Sprachen deutsch, englisch, französisch und spanisch. Zudem enthält das neue Lieferverzeichnis zahlreiche Unternehmensporträts von namhaften Playern der Branche sowie einen länderspezifischen Überblick über den russischen Aluminiummarkt. Die Online-Version des Lieferverzeichnisses steht im Internet unter www.alu-lieferverzeichnis.de allen Nutzern kostenlos zur Verfügung. Dies ermöglicht eine schnelle, strukturierte und einfache Recherche anhand einer detaillierten Produktgliederung mit umfangreichen Suchfunktionen. Das Aluminium-Lieferverzeichnis 2010 ist in deutsch/englisch abgefasst und kostet EUR 16,50 zzgl. Versandkosten.

Weitere Infos: Anne Tappen-Hamacher Aluminium-Verlag Marketing Kommunikation GmbH Tel.: +49 (0)211 4796 130 www.alu-verlag.de [email protected]

Aluminium Suppliers Directory 2010 The latest Aluminium Suppliers Directory 2010 has now been published – and therewith the most comprehensive and up-to-date reference work for the aluminium industry and its peripherals – worldwide. It lists several companies in the aluminium producing and processing industry, the supplier industry, the metal dealers and the most diverse service providers. This is where companies present their multifarious products and services from production via equipment to application, aided by the detailed, classified product categories. Technical market information, particularly comprehensive trade references and test institution addresses complete the directory. The 2010 edition of Aluminium Suppliers Directory will again include an overview of the aluminium market in a specific region: the focus this year is on Russia. New is a multi-lingual dictionary in English, French, German and Spanish, which you will find on pages 375 to 421, that is taken from the Glossary of Technical Terns series. The second part covers selected terms from the section M-Z of Extrusion of Metals, which was first published in the 1990s. The dictionary finds thereby its continuation. The Aluminium Directory 2010 is issued as a German/English publication and costs 16.50 euros plus postal charges. For further information see contact information on the left.

Verfahren zur Herstellung einer Aero­ soldose aus Aluminium aus einem Blechbund sowie Aerosoldose aus Aluminium. Exal Corporation, Yongstown, OH 44502, US. (B21D 22/28, EPA 2119515, EP-AT: 27.06.2003)

2115182, EP-AT: 16.01.2008)

Gießkern zur Bildung eines Kühlkanals. Mahle International GmbH, 70376 Stuttgart, DE. (B22C 9/10, OS 10 2008 020 231, AT: 22.04.2008)

Gerolltes Al­Mg­Si­Legierungsprodukt mit guter Hemmung. Aleris Aluminium Duffel BVBA, 2570 Duffel, BE. (B32B 15/01, EPA 2110235, EP-AT: 22.10.2008)

Verbindung zwischen einem Rohrprofil aus Stahl und einem Bauteil aus Alumi­ nium. Benteler Automobiltechnik GmbH, 33102 Paderborn, DE. (B23K 20/16, PS 10 2008 037 709, AT: 14.08.2008)

Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F16J 1/16, EPA 2094997, EPAT: 23.10.2007)

Glänzende Beschichtungen für Alumi­ nium­ oder Stahlkraftfahrzeugrädern und deren Herstellung. Daimler AG, 70327 Stuttgart, DE. (C23K 14/06, EPA

L12­Aluminiumlegierungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/16, EPA 2110453, EP-AT: 31.03.2009)

Zweiteiliger Kolben für einen Ver­ brennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, PS 50 2005 005 495, EP 1859155, EP-AT: 28.11.2005)

60

Produkt aus einer Al­Mg­Legierung für Panzerplatten. Aleris Aluminium Koblenz GmbH, 56070 Koblenz, DE. (C22C 1/06, EPA 2118327, EP-AT: 12.02.2008)

ALUMINIUM · 3/2010

PAt e N t e

Wärmebehandlungsfähige L12­Alumi­ niumlegierungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/04, EPA 2112242,EP-AT: 31.03.2009) L12­Aluminiumlegierungen mit ho­ her Festigkeit. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/06, C22C 21/10 u. C22C 21/16, EPA 2112243, EP 2112244 u. EPA 2110452, EP-AT: 31.03.2009) Hochfeste L12­Aluminiumlegierungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/00, EPA 2110450, EP-AT: 31.03.2009) L12­Aluminiumlegierungen mit bimo­ daler und trimodaler Verteilung. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/02, EPA 2110451, EP-AT: 31.03.2009) Hochfeste Aluminiumlegierungen mit L12­Ausscheidungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/00, EPA 2112239, EP-AT: 31.03.2009) Dispersionsverstärkte L12­Aluminium­ legierungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/00, EPA 2112240, EP-AT: 31.03.2009) L12­verstärkte amorphe Aluminiumle­ gierungen. United Technologies Corp., Hartford, CT 06101, US. (C22C 21/00, EPA 2112241, EP-AT: 31.03.2009) Aluminium­Wärmeübertrager. Behr GmbH & Co. KG, 70469 Stuttgart, DE. (F28F 21/08, PS 101 06 510, AT: 13.02.2001) Anodische Oxidschicht für elektrische Leiter, insbesondere Leiter aus Alumi­ nium, Verfahren zur Erzeugung einer anodischen Oxidschicht und elektri­ scher Leiter mit anodischer Oxidschicht. Steinert Elektromagnetbau GmbH, 50933 Köln, DE. (H01B 3/10, OS 10 2006 052 170, AT: 02.11.2006) Al­Si­Legierung mit reduzierter Nei­ gung zum Kleben an Druckguss­ formen. Brunswick Corp., Lake Forest, Ill., US. (C22C 21/04, EP 1 683 881, EPAT: 02.08.2005)

stoffs. Siemens AG, 80333 München, DE. (C08K 3/08, OS 10 2008 025 484, AT: 28.05.2008) Aluminium­ oder Aluminiumlegie­ rungs­Verbundwerkstoffkomponen­ ten im Verbund mit Vorformlingstruk­ turen. Mazda Motor Corp., Hiroshima, JP. (C22C 49/14, PS 197 12 808, AT: 26.03.1997)

Verfahren zur Herstellung eines Blechs aus harzbeschichteter Aluminiumlegie­ rung für gezogene und abgestreckte Dosen. Toyo Kohan Co., Ltd., Tokio/Tokyo, JP. (C22C 21/06, PS 197 81 716, WO 1997/038148, AT: 10.04.1997, WO-AT: 10.04.1997)

Vorrichtung zur Sicherung von als Pa­ ket gelagerten Aluminium­Strangguss­ produkten, sog. 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 eines Bau­ teils aus einer Aluminiumlegierung durch Druckgießen. BDW technologies GmbH, 85570 Markt Schwaben, DE. (C22F 1/043, PS 599 03 009, EP 0997550, EP-AT: 15.04.1999)

Gegenstand mit einem Flächenelement aus Aluminium. Sommer GmbH, 71691 Freiberg, DE. (B41M 1/28, GM 20 2006 014 584, AT: 20.09.2006)

Hitzebeständige und hochzähe Alumi­ niumlegierung und Herstellungsver­ fahren dafür und Motorenteile. Honda Motor Co., Ltd., Tokyo, JP; Sumitomo Electric Sintered Alloy, Ltd., Okayama, JP. (C22C 21/02, EP 1 690 953, EP-AT: 02.12.2004

Aluminium­Lastwiderstand. Türk & Hillinger GmbH, 78532 Tuttlingen, DE. (H01C 1/084, GM 20 2008 014 586, AT: 03.11.2008) Plattenfeinschieblehre 1000 mm aus Aluminium (Schreinerschieblehre). Simmat, Rainer, 33790 Halle, DE. (G01B 3/20, GM 20 2009 004 466, AT: 31.03.2009) Aluminiumgleitlagerlegierung. Deutsches Zentrum für Luft- und Raumfahrt e.V., 51147 Köln, DE; Technische Universität Clausthal, 38678 Clausthal-Zellerfeld, DE. (C22C 21/00, PS 50 2005 006 241, EP 1888798, EP-AT: 07.06.2005) Drehtrommelofen mit feuerfesten Rührkörpern zum Umschmelzen von Aluminium. Metallhüttenwerke Bruch GmbH, 44145 Dortmund, DE. (C22B 21/ 00, EP 1 725 690, EP-AT: 17.03.2005) Aluminiumkolben, der zumindest teil­ weise mit einem Aluminiumoxidfilm bedeckt ist. Aisin Seiki K.K., Kariya, Aichi, JP. (C25D 1/00, PS 60 2005 011 738, EP 1657326, EP-AT: 15.11.2005) Aluminiumsystem Kühler. Benteler Automobiltechnik GmbH, 33102 Paderborn, DE. (F28F 21/08, PS 10 2007 015 146, AT: 29.03.2007) Elektrischer Draht mit Aluminium­ oder Aluminiumlegierungskern. Nexans, Paris, FR. (C25D 7/06, EP 1 700 933, EP-AT: 03.02.2006

Leichter Universal­Gerüstboden aus Aluminium und Kunststoff im Baukas­ tensystem und Verfahren zur Herstel­ lung des Gerüstbodens. UTI Holding + Management AG, 60487 Frankfurt, DE. (E04G 5/08, OS 10 2008 023 525, AT: 15.05.2008)

Ultraleichte und parfümierte Kompasse aus einer Aluminiumlegierung. Kronos SRL, 24040 Palosco (BG), IT. (B43L 9/02, EPA 2116392, EP-AT: 05.06.2008)

Wärmeleitfähiger Verbundwerkstoff mit Aluminiumpulver, Verfahren zum Herstellen des Verbundwerkstoffs und Verwendung des Verbundwerk­

Aluminiumlegierung für Metallschäu­ me, ihre Verwendung und Verfahren zur Herstellung. Helmholtz-Zentrum Berlin für Materialien und Energie

ALUMINIUM · 3/2010

GmbH, 14109 Berlin, DE. (C22C 21/06, OS 10 2008 027 798, AT: 11.06.2008)

Folie aus Aluminiumlegierung und Ver­ fahren zu deren Herstellung. Novelis Inc., Toronto, Ontario, CA. (C22C 21/02, PS 60 2006 004 594, EP 1902149, EP-AT: 29.06.2006) Verfahren zur Herstellung von Blech aus einer Aluminiumlegierung. Alcoa Inc., Pittsburgh, Pa., US. (C22F 1/057, PS 691 25 436, EP 0473122, EP-AT: 27.08.1991) Zähe Aluminiumlegierung mit Kupfer und Magnesium. Alcoa Inc., Alcoa Center, Pa., US. (C22C 21/00, PS 693 26 838, EP 0656956, EP-AT: 27.08.1993) Aluminiumlegierung für Verkehrsflug­ zeugflügel. Alcoa Inc., Alcoa Center, Pa., US. (C22F 1/04, PS 696 29 113, 0829552, EP-AT: 11.09.1996) Verfahren zum Herstellen von Zylin­ derblöcken aus Leichtmetall mit einge­ schweißten Leichtmetall­Zylinderbüch­ sen und Einrichtung zur Durchführung des Verfahrens. Volkswagen AG, 38440 Wolfsburg, DE. (B23P 13/00, PS 100 19 783, AT: 20.04.2000) Schleuderstrahlanlage zum Strahlen von Werkstücken aus Leichtmetallle­ gierungen. Disa Industrie AG, Schaffhausen, CH. (B24C 3/18, PS 50 2005 006 059, EP 1714742, EP-AT: 21.04.2005) Magnesiumlegierung. Stolfig, Peter, 85290 Geisenfeld, DE. (C22C 23/00, GM 202 02 591, AT: 20.02.2002) Verfahren zur Herstellung eines Bau­ materials aus magnesiumhaltiger Le­ gierung auf Aluminiumbasis. Advanced Alloys SA, 1201 Genéve, CH. (C22C 1/02, EPA 2113576, EP-AT: 24.01.2007)

61

PAt e N t e

Magnesiumlegierungsdraht. Sumitomo Electric Industries, Ltd., Osaka-shi, Osaka 541-0041, JP; Sumitomo (SEI) Steel Wire Corp., Itama-shi, Hyogo 664-0016, JP. (C22C 23/02, EPA 2113579, EP-AT: 16.05.2002) Kriechbeständige Magnesiumlegie­ rung mit guter Bruchfestigkeit im Un­ terdruckgießverfahren. Dead Sea Magnesium Ltd., Beer-Sheva, IL; Volkswagen AG, 38440 Wolfsburg, DE. (C22C 23/06, EP 1 897 962, EP-AT: 29.09.2006) Legierungen der Serie 2000 mit Scha­ denstoleranzleistung für Luft­ und Raumfahrtanwendungen. Alcoa Inc., Pittsburgh, Pa., US. (C22C 21/00, GM 20 2006 020 514, AT: 07.09.2006) Korrosionsbeständige Legierungen der 6000­Serien, verwendbar für die Luftfahrt. Alcoa Inc., Pittsburgh, Pa., US. (C22C 21/08, PS 601 08 382, EP 1290235, EP-AT: 01.06.2001) Fahrzeugrahmenbauteile mit verbes­ serter Energieabsorptionsfähigkeit, Verfahren zu ihrer Herstellung und eine Legierung. Alcoa Inc., Pittsburgh, Pa., US. (C22C 21/08, PS 696 33 002, EP 0805219, EP-AT: 03.05.1996) Verbundmetalltafel und Herstellungs­ verfahren dafür. Alcan Rhenalu, 92400 Courbevoie, FR. (E04C 2/34, EPA 2115233, WO 2008/113911, EP-AT: 08.02.2008, WO-AT: 08.02.2008 Deckfolie für Blisterverpackungen. Alcan Technology & Management Ltd., 8212 Neuhausen am Rheinfall, CH. (B65D 75/34, EPA 2112090, EP-AT: 22.04.2008) Verpackungsdeckfolie, Behältnis, Ver­ packung und Verpackungsproduktein­ heit. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH. (B65D 65/40, OS 10 2008 023 952, AT: 16.05.2008) Aluminiumlegierungsstreifen zum Schweißen. Alcan Rhenalu, Paris, FR; Alcan Rolled Products Ravenswood LLC, Ravenswood, W.Va., US. (B23K 1/00, PS 60 2004 018 970, EP 1687115, EP-AT: 24.11.2004) Verfahren zur Herstellung hochfester und ermüdungsfester Aluminiumlegie­ rungsprodukte. Alcan Rhenalu, Paris, FR. (C22F 1/053, PS 60 2005 011 619, EP 1766102, EP-AT: 22.06.2005) Fenster, Fenstertür oder dergleichen mit einem belüfteten Rahmen, mit Fluidverbindungsmitteln von einer Luftschicht zur Außenumgebung über eine Profildichtung im unteren Quer­ träger der Außenglasscheibe. Norsk

62

Hydro ASA, Oslo, NO. (E06B 3/673, EP 1 700 992, EP-AT: 09.03.2006) Anlage und Verfahren zur Verarbei­ tung linear geschmolzener Metalle mithilfe eines Salzreaktants in einem Tiefbettentgaser. Alcoa Inc., Pittsburgh, PA 15069-0001, US. (C22B 9/10, EPA 2113033, WO 2008/103912, EP-AT: 22.02.2008, WO-AT: 22.02.2008) System zur Zufuhr von Metallschmelze unter konstantem Druck und Verfah­ ren zur Herstellung von Endlosmetall­ artikeln. Alcoa Inc., Pittsburgh, Pa., US. (B22D 11/00, PS 602 13 977, EP 1395380, EP-AT: 18.04.2002) Fahrzeugrahmenbauteile mit verbes­ serter Energieabsorptionsfähigkeit, Verfahren zu ihrer Herstellung und eine Legierung. Alcoa Inc., Pittsburgh, Pa., US. (C22C 21/08, PS 696 33 002, EP 0805219, EP-AT: 03.05.1996)

eines Luftspaltes mit der Außenumge­ bung durch eine Außenglasscheibe und eine diese Scheibe haltende Lei­ ste. Norsk Hydro ASA, Oslo, NO. (E06B 3/673, EP 1 700 993, EP-AT: 09.03.2006) Koaxialprofil und Verfahren zur Her­ stellung eines solchen Koaxialprofils. Erbslöh Aluminium GmbH, 42553 Velbert, DE. (F16L 9/18, F28D 7/10, PS 10 2008 022 933, EPA 2116803, AT: 09.05.2008, EP-AT: 05.05.2009) Gebäudefassade oder Dachfassade mit Ausfachungen. Hermann Gutmann Werke AG, 91781 Weissenburg, DE. (E04B 2/96, OS 10 2008 022 650, EPA 2116659, AT: 07.05.2008,EP-AT: 04.04.2009) Fensterkonstruktion, insb. Dachfens­ terkonstruktion. Hermann Gutmann Werke AG, 91781 Weißenburg, DE. (E06B 3/30, GM 20 2006 014 581, AT: 20.09.2006

Kühlungssystem für eine Bandstrang­ gießanlage und damit zusammenhän­ gende Verfahren. Alcoa Inc., Pittsburgh, Pa., US. (B22D 11/06, PS 697 15 371, EP 0873211, EP-AT: 08.01.1997)

Kolben für einen Verbrennungsmotor und Verfahren zu seiner Herstellung. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/16, OS 10 2008 028 197, AT: 12.06.2008)

Gegossene Rahmenelemente für Kraft­ fahrzeuge. Alcoa Inc., Pittsburgh, Pa., US. (B62D 29/00, PS 699 12 795, EP 1100714, EP-AT: 02.08.1999)

Verfahren und Vorrichtung zur Erhö­ hung der Wärmebeständigkeit und der Alterungsstabilität von Alumi­ niumblechen und hergestellte Pro­ dukte. Reynolds Metals Co., Richmond, Va., US. (C21D 9/46, PS 696 28 044, EP 0874917, EP-AT: 17.12.1996, WO-AT: 17.12.1996)

Längliches Halteelement. Corus Bausysteme GmbH, 56070 Koblenz, DE. (E04D 3/362, GM 203 80 217, AT: 29.08.2003) Tür, Fenster oder dergleichen in wärme­ gedämmter Ausführung. Norsk Hydro ASA, 0257 Oslo 2, NO. (E06B 3/263, EPA 2116685, EP-AT: 25.04.2009) Ausfachungsrahmen für Gebäudefas­ saden. Hydro Aluminium AS, Oslo, NO. (E04B 2/96, OS 10 2008 030 786, AT: 28.06.2008) Druckplattenträger und Verfahren zur Herstellung eines Druckplattenträgers oder einer Offsetdruckplatte. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B41N 1/08, PS 199 02 527, AT: 22.01.1999) Verfahren zur Herstellung eines Be­ hälters aus Aluminiumblechen. Hydro Aluminium Deutschland GmbH, 51149 Köln, DE. (B21D 51/24, EP 2 026 920, WO 2007/141217, EP-AT: 01.06.2007, WO-AT: 01.06.2007) Wetterschutzschiene sowie Tür bzw. Fenster. Hermann Gutmann Werke AG, 91781 Weißenburg, DE. (E06B 1/34, GM 20 2008 008 486, AT: 26.06.2008) Belüftetes Fenster, Fenstertür oder dergleichen, mit einer Fluidverbindung

Verfahren zur Herstellung von Alumi­ niummaterial für eine Elektrode eines elektrolytischen Kondensators. Showa Denko K.K., Tokio/Tokyo, JP. (C22F 1/04, PS 603 29 004, EP 1541704, EP-AT: 25.06.2003, WO-AT: 25.06.2003)

ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige, den Werkstoff Aluminium betreffende Patente. Die ausführlichen Patentblätter und auch weiterführende Informationen dazu stehen der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen bei der

Mitteldeutschen Informations-, Patent-, Online-Service GmbH (mipo), Julius-Ebeling-Str. 6, D-06112 Halle an der Saale, Tel. 0345/29398-0 Fax 0345/29398-40, www.mipo.de Die Gesellschaft bietet darüber hinaus weitere Patent-Dienstleistungen an.

ALUMINIUM · 3/2010

International Journal for Industry, Research and Application How do your products and services come to appear every month in the list of supply sources, on the internet – www.Alu-web.de – and in the annual list of supply sources published by ALUMINIUM ? 





Please mark the main group relevant to you

q

Smelting technology

q

Rolling technology

q

Extrusion

q

Foundry

Indicate the sub-group and/or key word (if necessary, ask us for the list of key words) _______________________

_______________________

_______________________

_______________________

_______________________

_______________________

Enter your text, not forgetting your on-line address:

Line 1: ............................................................................................................................................ Line 2: ............................................................................................................................................ Line 3: ............................................................................................................................................ Line 4: ............................................................................................................................................ Line 5: ............................................................................................................................................ Line 6: ............................................................................................................................................ (Maximum 35 characters per line, including spaces. Price per line for each issue EUR 5,50 + VAT – minimum order 10 issues = 1 year. Logos are calculated according to the lines they occupy: 1 line = 2 mm). _______________________________________________________________ Place/Date Company stamp / Signature



… and send this form to us by fax or post:

Fax number +49-511/7304-157

For information Tel.: -142

Giesel Verlag GmbH, ALUMINIUM Rehkamp 3, D-30916 Isernhagen

We will gladly send you a quotation!

Lieferverzeichnis

1 Smelting technology Hüttentechnik

1.1 Raw materials 1.2 Storage facilities for smelting 1.3 Anode production 1.4 Anode rodding 1.4.1 Anode baking 1.4.2 Anode clearing 1.4.3 Fixing of new anodes to the anodes bars 1.5 Casthouse (foundry) 1.6 Casting machines 1.7 Current supply 1.8 Electrolysis cell (pot) 1.9 Potroom 1.10 Laboratory 1.11 Emptying the cathode shell 1.12 Cathode repair shop 1.13 Second-hand plant 1.14 Aluminium alloys 1.15 Storage and transport 1.16 Smelting manufactures

1.1 Raw Materials/Rohstoffe  Raw Materials / Rohstoffe

1.1 Rohstoffe 1.2 Lagermöglichkeiten in der Hütte 1.3 Anodenherstellung 1.4 Anodenschlägerei 1.4.1 Anodenbrennen 1.4.2 Anodenschlägerei 1.4.3 Befestigen von neuen Anoden an der -stange 1.5 Gießerei 1.6 Gießmaschinen 1.7 Stromversorgung 1.8 Elektrolyseofen 1.9 Elektrolysehalle 1.10 Labor 1.11 Ofenwannenentleeren 1.12 Kathodenreparaturwerkstatt 1.13 Gebrauchtanlagen 1.14 Aluminiumlegierungen 1.15 Lager und Transport 1.16 Hüttenerzeugnisse

 Conveying systems bulk materials Förderanlagen für Schüttgüter (Hüttenaluminiumherstellung)

 Hydraulic presses for prebaked anodes / Hydraulische Pressen zur Herstellung von Anoden

FLSmidth MöLLer GmbH Internet: www.flsmidthmoeller.com see Storage facilities for smelting 1.2 TrIMeT ALuMInIuM AG Aluminiumallee 1 D-45356 Essen Tel.: +49 (0) 201 / 3660 Fax: +49 (0) 201 / 366506 E-Mail: [email protected] Internet: www.trimet.de

1.2 Storage facilities for smelting

 Exhaust gas treatment Abgasbehandlung

Solios Carbone – France www.solios.com

 Unloading/Loading equipment

Entlade-/Beladeeinrichtungen FLSmidth MöLLer GmbH www.flsmidthmoeller.com see Storage facilities for smelting 1.2

 Mixing Technology for Anode pastes

Lagermöglichkeiten i.d. Hütte

FLSmidth MöLLer GmbH Haderslebener Straße 7 D-25421 Pinneberg Telefon: 04101 788-0 Telefax: 04101 788-115 E-Mail: [email protected] Internet: www.flsmidthmoeller.com Kontakt: Herr Dipl.-Ing. Timo Letz

LAeIS GmbH Am Scheerleck 7, L-6868 Wecker, Luxembourg Phone: +352 27612 0 Fax: +352 27612 109 E-Mail: [email protected] Internet: www.laeis-gmbh.com Contact: Dr. Alfred Kaiser

ALuMInA And peT COke SHIpunLOAderS Contact: Andreas Haeuser, [email protected]

Mischtechnologie für Anodenmassen

1.3 Anode production Anodenherstellung

Buss AG CH-4133 Pratteln Phone: +41 61 825 66 00 E-Mail: [email protected] Internet: www.busscorp.com

see Storage facilities for smelting 1.2 Outotec GmbH Albin-Köbis-Str. 8, D-51147 Köln Phone: +49 (0) 2203 / 9921-0 E-mail: [email protected] www.outotec.com

Solios Carbone – France www.solios.com

 Auto firing systems

 Open top and closed type baking furnaces

rIedHAMMer GmbH D-90411 Nürnberg Phone: +49 (0) 911 5218 0, Fax: -5218 231 E-Mail: [email protected] Internet: www.riedhammer.de

rIedHAMMer GmbH D-90411 Nürnberg Phone: +49 (0) 911 5218 0, Fax: -5218 231 E-Mail: [email protected] Internet: www.riedhammer.de

Automatische Feuerungssysteme

Offene und geschlossene Ringöfen

 Bulk materials Handling from Ship to Cell

Bulk materials Handling from Ship to Cell

www.coperion.com mailto: [email protected]

64

ALUMINIUM · 3/2010

Lieferverzeichnis

1.4 Anode rodding

Anodenanschlägerei

1.4.3 Fixing of new anodes to the anodes bars

Befestigen von neuen Anoden a. d. Anodenstange

 Fixing the nipples to the anodes by casting in see Storage facilities for smelting 1.2

 Removal of bath residues from the surface of spent anodes Entfernen der Badreste von der Oberfläche der verbrauchten Anoden

GLAMA Maschinenbau GmbH Hornstraße 19 D-45964 Gladbeck Telefon 02043 / 9738-0 Telefax 02043 / 9738-50

Befestigen der Nippel mit der Anode durch Eingießen SerMAS InduSTrIe E-Mail: [email protected] see Casting Machines 1.6

1.5 Casthouse (foundry) Gießerei

Hampshire House, High Street, Kingswinford, West Midlands DY6 8AW, UK Tel.: +44 (0) 1384 279132 Fax: +44 (0) 1384 291211 E-Mail: [email protected] www.mechatherm.com

 Transport of finished anode elements to the pot room

1.4.1 Anode baking Anodenbrennen

Entgasung, Filtern, Kornfeinung

drache umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: www.drache-gmbh.de Gautschi engineering GmbH see Casting equipment 3.1

 Dross skimming of liquid metal

Abkrätzen des Flüssigmetalls GLAMA Maschinenbau GmbH see Anode rodding 1.4

 Dross skimming of the melt Abkrätzen der Schmelze

E-Mail: [email protected] see Casting machines 1.6

Transport der fertigen Anodenelemente in Elektrolysehalle

Hovestr. 10 . D-48431 Rheine Telefon + 49 (0) 59 71 58-0 Fax + 49 (0) 59 71 58-209 E-Mail [email protected] Internet www.windhoff.de

 Degassing, filtration and grain refinement

HerTWICH enGIneerInG GmbH Maschinen und Industrieanlagen Weinbergerstraße 6, A-5280 Braunau am Inn Phone +437722/806-0 Fax +437722/806-122 E-Mail: [email protected] Internet: www.hertwich.com InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH Konstantinstraße 1a D 41238 Mönchengladbach Telefon +49 (02166) 987990 Telefax +49 (02166) 987996 E-Mail: [email protected] Internet: www.inotherm-gmbh.de

 Anode charging

 Furnace charging with molten metal

Ofenbeschickung mit Flüssigmetall GLAMA Maschinenbau GmbH see Anode rodding 1.4

 Melting/holding/casting furnaces Schmelz-/Halte- und Gießöfen

Gautschi engineering GmbH see Casting equipment 3.1 Solios Carbone – France www.solios.com

Anodenchargieren

SerMAS InduSTrIe E-Mail: [email protected] see Casting Machines 1.6

 Anode storage

Anodenlager SerMAS InduSTrIe E-Mail: [email protected] see Casting Machines 1.6

see Equipment and accessories 3.1 Stopinc AG Bösch 83 a CH-6331 Hünenberg Tel. +41/41-785 75 00 Fax +41/41-785 75 01 E-Mail: [email protected] Internet: www.stopinc.ch

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Clay / Tonerde

1.4.2 Anode clearing

Anodenschlägerei

 Separation of spent anodes from the anode bars

Trennen von den Anodenstangen

SerMAS InduSTrIe E-Mail: [email protected] see Casting Machines 1.6

ALUMINIUM · 3/2010

TrIMeT ALuMInIuM AG Aluminiumallee 1 D-45356 Essen Tel.: +49 (0) 201 / 3660 Fax: +49 (0) 201 / 366506 E-Mail: [email protected] Internet: www.trimet.de

Sistem Teknik Ltd. Sti. DES San. Sit. 102 SOK No: 6/8 Y.Dudullu, TR-34775 Istanbul/Turkey Tel.: +90 216 420 86 24 Fax: +90 216 420 23 22 E-Mail: [email protected] Internet: www.sistemteknik.com

65

Lieferverzeichnis

 Metal treatment in the holding furnace

Metallbehandlung in Halteöfen Gautschi engineering GmbH see Casting equipment 3.1

 Transfer to the casting furnace

 Rolling and extrusion ingot and T-bars

Formatgießerei (Walzbarren oder Pressbolzen oder T-Barren) Gautschi engineering GmbH see Casting equipment 3.1

 Heat treatment of extrusion ingot (homogenisation)

Formatebehandlung (homogenisieren)

Gautschi engineering GmbH see Casting equipment 3.1

Überführung in Gießofen

GLAMA Maschinenbau GmbH see Anode rodding 1.4 drache umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: www.drache-gmbh.de

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

Gautschi engineering GmbH see Casting equipment 3.1

Horizontales Stranggießen Gautschi engineering GmbH see Casting equipment 3.1

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Horizontal continuous casting

Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4

see Billet Heating Furnaces 1.5

 Vertical semi-continuous DC casting / Vertikales Stranggießen Gautschi engineering GmbH see Casting equipment 3.1

 Transport of liquid metal to the casthouse

Transport v. Flüssigmetall in Gießereien

GLAMA Maschinenbau GmbH see Anode rodding 1.4 MArx GmbH & Co. kG www.marx-gmbh.de see Melt operations 4.13 Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Scales / Waagen Gautschi engineering GmbH see Casting equipment 3.1

1.8 Electrolysis cell (pot)

 Treatment of casthouse off gases

Elektrolyseofen

Behandlung der Gießereiabgase

Gautschi engineering GmbH see Casting equipment 3.1 Solios Carbone – France www.solios.com

1.6 Casting machines Gießmaschinen

Wagstaff, Inc. 3910 N. Flora Rd. Spokane, WA 99216 USA +1 509 922 1404 phone +1 509 924 0241 fax E-Mail: [email protected] Internet: www.wagstaff.com

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Sawing / Sägen Gautschi engineering GmbH see Casting equipment 3.1

 Bulk materials Handling from Ship to Cell

Bulk materials Handling from Ship to Cell

www.coperion.com mailto: [email protected]

 Calcium silicate boards Calciumsilikatplatten

promat GmbH – Techn. Wärmedämmung Scheifenkamp 16, D-40878 Ratingen Tel. +49 (0) 2102 / 493-0, Fax -493 115 [email protected], www.promat.de

www.mechatherm.com see Smelting technology 1.5

 Pig casting machines (sow casters) Masselgießmaschine (Sowcaster)

Gautschi engineering GmbH see Casting equipment 3.1

see Storage facilities for smelting 1.2

66

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Exhaust gas treatment Abgasbehandlung

Solios Carbone – France www.solios.com 343 Chemin du Stade 38210 Saint Quentin sur Isère Tel. +33 (0) 476 074 242 Fax +33 (0) 476 936 776 E-Mail: [email protected] Internet: www.sermas.com

 Pot feeding systems

Beschickungseinrichtungen für Elektrolysezellen

FLSmidth MöLLer GmbH www.flsmidthmoeller.com see Storage facilities for smelting 1.2

ALUMINIUM · 3/2010

Lieferverzeichnis

1.9 Potroom

Elektrolysehalle

T.T. Tomorrow Technology S.p.A. Via dell’Artigianato 18 Due Carrare, Padova 35020, Italy Telefon +39 049 912 8800 Telefax +39 049 912 8888 E-Mail: [email protected] Contact: Giovanni Magarotto

 Anode changing machine Anodenwechselmaschine

GLAMA Maschinenbau GmbH see Anode rodding 1.4

 HF Measurementtechnology

HF Messtechnik OpSIS AB Box 244, S-24402 Furulund, Schweden Tel. +46 (0) 46-72 25 00, Fax -72 25 01 E-Mail: [email protected] Internet: www.opsis.se

 Tapping vehicles/Schöpffahrzeuge GLAMA Maschinenbau GmbH see Anode rodding 1.4

GLAMA Maschinenbau GmbH see Anode rodding 1.4

Ofenwannenentleeren

 Cathode bar casting units Kathodenbarreneingießanlage

E-Mail: [email protected] see Casting machines 1.6

1.14 Aluminium Alloys

Aluminiumlegierungen

 Crustbreakers / Krustenbrecher GLAMA Maschinenbau GmbH see Anode rodding 1.4

 Dry absorption units for electrolysis exhaust gases Trockenabsorptionsanlage für Elektrolyseofenabgase

Solios Carbone – France www.solios.com

2

Lager und Transport

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

1.11 Emptying the cathode shell

 Anode transport equipment Anoden Transporteinrichtungen

1.15 Storage and transport

rHeInFeLden ALLOYS GmbH & Co. kG A member of ALUMINIUM RHEINFELDEN Group Postfach 1703, 79607 Rheinfelden Tel.: +49 7623 93-490 Fax: +49 7623 93-546 E-Mail: [email protected] Internet: www.rheinfelden-alloys.eu

Hier könnte Ihr

Bezugsquellen-Eintrag stehen. Rufen Sie an: Beate Schaefer, Tel: 0511 7304-148

1.16 Smelting manufactories Hüttenerzeugnisse

 Rolling ingots Walzbarren

Alcan Aluminium Valais SA CH-3960 Sierre Telefon: 0041 27 / 4575111 Telefax: 0041 27 / 4576425

Extrusion

Strangpressen

2.1 Extrusion billet preparation 2.1.1 Extrusion billet production 2.2 Extrusion equipment 2.3 Section handling 2.4 Heat treatment 2.5 Measurement and control equipment 2.6 Die preparation and care 2.7 Second-hand extrusion plant 2.8 Consultancy, expert opinion 2.9 Surface finishing of sections 2.10 Machining of sections 2.11 Equipment and accessories 2.12 Services

2.1 Extrusion billet preparation Pressbolzenbereitstellung

www.mechatherm.com see Smelting technology 1.5

www.alu-web.de

ALUMINIUM · 3/2010

2.1 Pressbolzenbereitstellung 2.1.1 Pressbolzenherstellung 2.2 Strangpresseinrichtungen 2.3 Profilhandling 2.4 Wärmebehandlung 2.5 Mess- und Regeleinrichtungen 2.6 Werkzeugbereitstellung und -pflege 2.7 Gebrauchte Strangpressanlagen 2.8 Beratung, Gutachten 2.9 Oberflächenveredlung von Profilen 2.10 Profilbearbeitung 2.11 Ausrüstungen und Hilfsmittel 2.12 Dienstleistungen

 Billet heating furnaces Öfen zur Bolzenerwärmung

Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de

MArx GmbH & Co. kG www.marx-gmbh.de see Melt operations 4.13

67

Lieferverzeichnis  Containers / Rezipienten

Sistem Teknik Ltd. Sti. DES San. Sit. 102 SOK No: 6/8 Y. Dudullu, TR-34775 Istanbul/Turkey Tel.: +90 216 420 86 24 Fax: +90 216 420 23 22 E-Mail: [email protected] Internet: www.sistemteknik.com

2.1.1 Extrusion billet production

SMS Meer GmbH see Extrusion equipment 2.2

Vollert Anlagenbau GmbH + Co. kG Stadtseestraße 12 D-74189 Weinsberg Tel. +49 (0) 7134 / 52-220 Fax +49 (0) 7134 / 52-222 E-Mail [email protected] Internet www.vollert.de

 Press control systems Pressensteuersysteme

Oilgear Towler GmbH

 Puller equipment

SMS Meer GmbH see Extrusion equipment 2.2

SMS Meer GmbH see Extrusion equipment 2.2

see Extrusion Equipment 2.2

Ausziehvorrichtungen/Puller

Pressbolzenherstellung

www.mechatherm.com see Smelting technology 1.5

 Billet transport and storage equipment

Bolzen-Transport- u. Lagereinricht.

 Temperature measurement Temperaturmessung

 Section cooling Profilkühlung

SerMAS InduSTrIe E-Mail: [email protected] See Casting Machines 1.6 SMS Meer GmbH see Extrusion equipment 2.2

2.2 Extrusion equipment

Strangpresseinrichtungen

 Heating and control equipment for intelligent billet containers

SMS Meer GmbH see Extrusion equipment 2.2

Heizungs- und Kontrollausrüstung für intelligente Blockaufnehmer

 Section saws

www.mechatherm.com see Smelting technology 1.5 Oilgear Towler GmbH Im Gotthelf 8 D 65795 Hattersheim Tel. +49 (0) 6145 3770 Fax +49 (0) 6145 30770 E-Mail: [email protected] Internet: www.oilgear.de

Profilsägen

MArx GmbH & Co. kG www.marx-gmbh.de see Melt operations 4.13

SMS Meer GmbH see Extrusion equipment 2.2

2.3 Section handling Profilhandling

 Packaging equipment

Verpackungseinrichtungen

SMS Meer GmbH Schloemann Extrusion Ohlerkirchweg 66 41069 Mönchengladbach, Germany Tel. +49 (0) 2161 350-0 Fax +49 (0) 2161 350-1667 E-Mail: [email protected] Internet: www.sms-meer.com

68

H+H HerrMAnn + HIeBer GMBH Fördersysteme für paletten und schwere Lasten Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 (0) 711 / 9 34 67-0 Fax +49 (0) 711 / 3 46 0911 E-Mail: [email protected] Internet: www.herrmannhieber.de

 Section store equipment Profil-Lagereinrichtungen

H+H HerrMAnn + HIeBer GMBH Fördersysteme für paletten und schwere Lasten Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 (0) 711 / 9 34 67-0 Fax +49 (0) 711 / 3 46 0911 E-Mail: [email protected] Internet: www.herrmannhieber.de

ALUMINIUM · 3/2010

Lieferverzeichnis  Transport equipment for extruded sections kASTO Maschinenbau GmbH & Co. kG Industriestr. 14, D-77855 Achern Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300 [email protected] / www.kasto.de Hersteller von Band- und Kreissägemaschinen sowie Langgut- und Blechlagersystemen

Transporteinrichtungen für Profilabschnitte

H+H HerrMAnn + HIeBer GMBH Fördersysteme für paletten und schwere Lasten Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 (0) 711 / 9 34 67-0 Fax +49 (0) 711 / 3 46 0911 E-Mail: [email protected] Internet: www.herrmannhieber.de

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

 Section transport equipment

 Heat treatment furnaces Wärmebehandlungsöfen

ELPO GmbH Kuchengrund 18 71522 Backnang Telefon 07191 9572-0 Telefax 07191 9572-29 E-Mail: [email protected] Internet: www.elpo.de InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH see Casthouse (foundry) 1.5

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

Profiltransporteinrichtungen

Hier könnte Ihr

Bezugsquellen-Eintrag stehen. Rufen Sie an: Beate Schaefer, Tel: 0511 7304-148 SMS Meer GmbH see Extrusion equipment 2.2

2.4 Heat treatment

Wärmebehandlung

Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans

 Stackers / Destackers Stapler / Entstapler

see Billet Heating Furnaces 2.1

 Custom designed heat processing equipment

Kundenspezifische Wärmebehandlungsanlagen

Sistem Teknik Ltd. Sti. see Billet Heating Furnaces 2.1

 Homogenising furnaces Homogenisieröfen

BSN Thermprozesstechnik GmbH Kammerbruchstraße 64 D-52152 Simmerath Tel. 02473-9277-0 · Fax: 02473-9277-111 [email protected] · www.bsn-therm.de Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

www.mechatherm.com see Smelting technology 1.5 SMS Meer GmbH see Extrusion equipment 2.2

 Stretching equipment Reckeinrichtungen

SeCO/WArWICk S.A. Sobieskiego 8, 66-200 Swiebodzin PL tel./fax +48 68 4111 600 (655) Fax +49 (0) 711 / 3 46 0911 [email protected] www.secowarwick.com.pl

SeCO/WArWICk S.A. see Heat treatment 2.4

 Annealing furnaces Glühöfen

SMS Meer GmbH see Extrusion equipment 2.2

ALUMINIUM · 3/2010

see Equipment and accessories 3.1

see Billet Heating Furnaces 2.1

69

Lieferverzeichnis

2.5 Measurement and control equipment

2.7 Second-hand extrusion plant

2.11 Equipment and accessories

 Extrusion plant control systems

Qualiteam International/extruprex Champs Elyséesweg 17, NL-6213 AA Maastricht Tel. +31-43-3 25 67 77 Internet: www.extruprex.com

 Inductiv heating equipment

Mess- und Regeleinrichtungen

Presswerkssteuerungen

Gebr. Strangpressanlagen

Ausrüstungen und Hilfsmittel

Induktiv beheizte Erwärmungseinrichtungen

2.8 Consultancy, expert opinion SMS Meer GmbH see Extrusion equipment 2.2

2.6 Die preparation and care Werkzeugbereitstellung und -pflege

Beratung, Gutachten

Dr.-Ing. Alexander Klaus, zert. Master Blackbelt Konrad-Adenauer-Str. 12, D-76877 Offenbach Tel.: +49 6348 247 67-0, Fax: 247 67-1 E-Mail: [email protected] Internet: www.klausleansigma.de

Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de

 Ageing furnace for extrusions Auslagerungsöfen für Strangpressprofile

 Die heating furnaces Werkzeuganwärmöfen

MArx GmbH & Co. kG www.marx-gmbh.de see Melt operations 4.13

do you need more information? E-Mail: [email protected]

2.10 Machining of sections Sistem Teknik Ltd. Sti. see Billet Heating Furnaces 2.1

Profilbearbeitung

see Billet Heating Furnaces 2.1

Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans

 Processing of Profiles Profilbearbeitung

2.12 Services

Dienstleistungen

Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans

Tensai (International) AG extal division Steinengraben 40 CH-4051 Basel Telefon +41 (0) 61 284 98 10 Telefax +41 (0) 61 284 98 20 E-Mail: [email protected]

 Process improvement and cost reduction

Prozessoptimierung und Kostensenkung

Klaus LeanSigma Technologie & Ci für die Aluminiumindustrie see Consultancy, expert opinion 2.8

Could not find your „keywords“? please ask for our complete „Supply sources for the aluminium industry“. e-Mail: [email protected]

70

ALUMINIUM · 3/2010

Lieferverzeichnis

3 Rolling mill technology Walzwerktechnik

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18

Casting equipment Rolling bar machining Rolling bar furnaces Hot rolling equipment Strip casting units and accessories Cold rolling equipment Thin strip / foil rolling plant Auxiliary equipment Adjustment devices Process technology / Automation technology Coolant / lubricant preparation Air extraction systems Fire extinguishing units Storage and dispatch Second-hand rolling equipment Coil storage systems Strip Processing Lines Productions Management Systems

3.0 Rolling mill technology Walzwerktechnik

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18

Gießanlagen Walzbarrenbearbeitung Walzbarrenvorbereitung Warmwalzanlagen Bandgießanlagen und Zubehör Kaltwalzanlagen Feinband-/Folienwalzwerke Nebeneinrichtungen Adjustageeinrichtungen Prozesstechnik / Automatisierungstechnik Kühl-/Schmiermittel-Aufbereitung Abluftsysteme Feuerlöschanlagen Lagerung und Versand Gebrauchtanlagen Coil storage systems Bandprozesslinien Produktions Management Systeme

 Electromagnetic Stirrer

Elektromagnetische Rührer Solios Carbone – France www.solios.com

 Filling level indicators and controls

Füllstandsanzeiger und -regler Gautschi engineering GmbH see Casting equipment 3.1 SMS Siemag Aktiengesellschaft Eduard-Schloemann-Straße 4 40237 Düsseldorf, Germany Telefon: +49 (0) 211 881-0 Telefax: +49 (0) 211 881-4902 E-Mail: [email protected] Internet: www.sms-siemag.com Geschäftsbereiche: Warmflach- und kaltwalzwerke Wiesenstraße 30 57271 Hilchenbach-Dahlbruch, Germany Telefon: +49 (0) 2733 29-0 Telefax: +49 (0) 2733 29-2852 Bandanlagen Walder Straße 51-53 40724 Hilden, Germany Telefon: +49 (0) 211 881-5100 Telefax: +49 (0) 211 881-5200 elektrik + Automation Ivo-Beucker-Straße 43 40237 Düsseldorf, Germany Telefon: +49 (0) 211 881-5895 Telefax: +49 (0) 211 881-775895 Graf-Recke-Straße 82 40239 Düsseldorf, Germany Telefon: +49 (0) 211 881-0 Telefax: +49 (0) 211 881-4902

Wagstaff, Inc.

Solios Carbone – France www.solios.com

 Melt purification units

Schmelzereinigungsanlagen Gautschi engineering GmbH see Casting equipment 3.1

 Metal filters / Metallfilter Gautschi engineering GmbH see Casting equipment 3.1

see Casting machines 1.6

 Melting and holding furnaces Schmelz- und Warmhalteöfen

Gautschi engineering GmbH Geschäftsbereich Aluminium Konstanzer Straße 37 Postfach 170 CH 8274 Tägerwilen Telefon +41/71/6666666 Telefax +41/71/6666688 E-Mail: [email protected] Kontakt: Stefan Blum, Tel. +41/71/6666621

 Metal pumps / Metallpumpen Solios Carbone – France www.solios.com

3.2 Rolling bar machining Walzbarrenbearbeitung

 Band saws / Bandsägen

SMS Meer GmbH see Extrusion equipment 2.2

3.1 Casting equipment

LOI Thermprocess GmbH Am Lichtbogen 29 D-45141 Essen Germany Telefon +49 (0) 201 / 18 91-1 Telefax +49 (0) 201 / 18 91-321 E-Mail: [email protected] Internet: www.loi-italimpianti.com

www.mechatherm.com see Smelting technology 1.5

SeCO/WArWICk S.A. see Heat treatment 2.4

SMS Meer GmbH see Extrusion equipment 2.2

 Slab milling machines Barrenfräsmaschinen

Gießanlagen

ALUMINIUM · 3/2010

71

Lieferverzeichnis

3.3 Rolling bar furnaces

 Roller tracks

BSN Thermprozesstechnik GmbH see Heat Treatment 2.4

Gautschi engineering GmbH see Casting equipment 3.1

Walzbarrenvorbereitung

Rollengänge

 Annealing furnaces Glühöfen

3.4 Hot rolling equipment

 Spools / Haspel

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Warmwalzanlagen

eBner Industrieofenbau Ges.m.b.H. Ruflinger Str. 111, A-4060 Leonding Tel. +43 / 732 / 68 68 Fax +43 / 732 / 68 68-1000 Internet: www.ebner.cc E-Mail: [email protected] Gautschi engineering GmbH see Casting equipment 3.1

 Hot rolling units / complete plants

Warmwalzanlagen/Komplettanlagen

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

see Cold rolling units / complete plants 3.6

see Equipment and accessories 3.1 schwartz GmbH

see Heat treatment 2.4

Solios Carbone – France www.solios.com

 Bar heating furnaces Barrenanwärmanlagen

eBner Industrieofenbau Ges.m.b.H. see Annealing furnaces 3.3 Gautschi engineering GmbH see Casting equipment 3.1

 Homogenising furnaces Homogenisieröfen

Gautschi engineering GmbH see Casting equipment 3.1

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

www.alu-web.de

72

3.5 Strip casting units and accessories

Bandgießanlagen und Zubehör

 Cores & shells for continuous casting lines  Coil transport systems Bundtransportsysteme

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3 Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4

 Drive systems / Antriebe

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Cores & shells for continuous casting lines

Bruno presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia

 Revamps, equipments & spare parts for continuous casting lines Revamps, equipments & spare parts for continuous casting lines

Bruno presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia

 Rolling mill modernisation

 Twin-roll continuous casting lines (complete lines)

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Bruno presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia

Walzwerksmodernisierung

Solios Carbone – France www.solios.com

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Twin-roll continuous casting lines (complete lines)

ALUMINIUM · 3/2010

Lieferverzeichnis

3.6 Cold rolling equipment Kaltwalzanlagen

 Cold rolling units / complete plants

Kaltwalzanlagen/Komplettanlagen

 Process optimisation systems Prozessoptimierungssysteme

Gautschi engineering GmbH see Casting equipment 3.1

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

 Process simulation Prozesssimulation

BSN Thermprozesstechnik GmbH see Heat Treatment 2.4 SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

 Coil annealing furnaces Bundglühöfen

Gautschi engineering GmbH see Casting equipment 3.1

 Drive systems / Antriebe

Gautschi engineering GmbH see Casting equipment 3.1

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

 Revamps, equipments & spare parts

see Equipment and accessories 3.1

Revamps, equipments & spare parts

 Heating furnaces / Anwärmöfen Gautschi engineering GmbH see Casting equipment 3.1

Bruno presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia

 Roll exchange equipment Walzenwechseleinrichtungen

SeCO/WArWICk S.A. see Heat treatment 2.4

Hier könnte Ihr

 Coil transport systems Bundtransportsysteme

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4

ALUMINIUM · 3/2010

BezugsquellenEintrag

stehen. Rufen Sie an: Tel. 0511 / 73 04-148 Beate Schaefer

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

Windhoff Bahn- und Anlagentechnik GmbH see Anode rodding 1.4

73

Lieferverzeichnis  Rolling mill modernization Walzwerkmodernisierung

3.7 Thin strip / foil rolling plant

Feinband-/Folienwalzwerke

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

 Thin strip / foil rolling mills / complete plant Feinband- / Folienwalzwerke / Komplettanlagen

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

see Cold rolling units / complete plants 3.6 see Cold rolling units / complete plants 3.6

Revamps, equipments & spare parts

 Slitting lines-CTL

Längs- und Querteilanlagen

 Coil annealing furnaces see Cold rolling units / complete plants 3.6

Bundglühöfen

Gautschi engineering GmbH see Casting equipment 3.1

 Strip shears

Bruno presezzi SpA Via per Ornago 8 I-20040 Burago Molgora (Mi) – Italy Tel. +39 039 63502 229 Fax +39 039 6081373 E-Mail: [email protected] Internet: www.brunopresezzi.com Contact: Franco Gramaglia

 Rolling mill modernization

Bandscheren

see Cold rolling units / complete plants 3.6

 Revamps, equipments & spare parts

Walzwerkmodernisierung

see Equipment and accessories 3.1

schwartz GmbH see Cold colling equipment 3.6

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

3.9 Adjustment devices SeCO/WArWICk S.A. see Heat treatment 2.4

Adjustageeinrichtungen

 Sheet and plate stretchers Blech- und Plattenstrecker

 Trimming equipment Besäumeinrichtungen

see Cold rolling units / complete plants 3.6

 Heating furnaces Anwärmöfen

Gautschi engineering GmbH see Casting equipment 3.1

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

www.alu-web.de

74

InOTHerM InduSTrIeOFenund WÄrMeTeCHnIk GMBH see Casthouse (foundry) 1.5

SMS Meer GmbH see Extrusion equipment 2.2

 Cable sheathing presses Kabelummantelungspressen

SMS Meer GmbH see Extrusion equipment 2.2

ALUMINIUM · 3/2010

Lieferverzeichnis

 Cable undulating machines Kabelwellmaschinen

 Strip thickness measurement and control equipment Banddickenmess- und -regeleinrichtungen

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0 SMS Meer GmbH see Extrusion equipment 2.2

 Transverse cutting units Querteilanlagen

ABB Automation Technologies AB Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor

SerMAS InduSTrIe E-Mail: [email protected] See Casting Machines 1.6

3.10 Process technology / Automation technology Prozesstechnik / Automatisierungstechnik

3.11 Coolant / lubricant preparation Kühl-/SchmiermittelAufbereitung

 Rolling oil recovery and treatment units

Walzöl-Wiederaufbereitungsanlagen

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

 Process control technology Prozessleittechnik

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

 Filter for rolling oils and emulsions

Filter für Walzöle und Emulsionen

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

Wagstaff, Inc.

see Casting machines 1.6

 Strip flatness measurement and control equipment Bandplanheitsmess- und -regeleinrichtungen

 Rolling oil rectification units

Hier könnte Ihr

BezugsquellenEintrag

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

Walzölrektifikationsanlagen

ABB Automation Technologies AB Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

stehen.

Rufen Sie an: Tel. 0511 / 73 04-148 Beate Schaefer

ALUMINIUM · 3/2010

75

Lieferverzeichnis

 Strip Annealing Lines

3.12 Air extraction systems

Bandglühlinien

Abluft-Systeme

 Exhaust air purification systems (active)

Abluft-Reinigungssysteme (aktiv)

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

3.17 Strip Processing Lines Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de

Bandprozesslinien

 Filtering plants and systems Filteranlagen und Systeme

 Strip Processing Lines Bandprozesslinien

 Colour Coating Lines Bandlackierlinien

www.bwg-online.com see Strip Processing Lines 3.17

SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

www.bwg-online.com see Strip Processing Lines 3.17

 Lithographic Sheet Lines

BWG Bergwerk- und WalzwerkMaschinenbau GmbH Mercatorstraße 74 – 78 D-47051 Duisburg Tel.: +49 (0) 203-9929-0 Fax: +49 (0) 203-9929-400 E-Mail: [email protected] Internet: www.bwg-online.com

Lithografielinien

www.bwg-online.com see Strip Processing Lines 3.17

3.18 Production Management systems

Produktions Management Systeme

see Cold rolling units / complete plants 3.6

dantherm Filtration GmbH Industriestr. 9, D-77948 Friesenheim Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 E-Mail: [email protected] Internet: www.danthermfiltration.com

 Stretch Levelling Lines Streckrichtanlagen

www.bwg-online.com see Strip Processing Lines 3.17

4production AG Production Optimising Solutions Carlo-Schmid-Str. 12, D-52146 Würselen Tel.: +49 (0) 2405 4135-0 [email protected], www.4production.com A PSI Group Company

3.14 Storage and dispatch Lagerung und Versand

Could not find your „keywords“? please ask for our complete SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

„Supply sources for the aluminium industry“.

3.16 Coil storage systems Bundlagersysteme

e-Mail: [email protected] SMS Siemag Aktiengesellschaft see Rolling mill technology 3.0

76

ALUMINIUM · 3/2010

Lieferverzeichnis

4 Foundry Gießerei

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19

Work protection and ergonomics Heat-resistant technology Conveyor and storage technology Mould and core production Mould accessories and accessory materials Foundry equipment Casting machines and equipment Handling technology Construction and design Measurement technology and materials testing Metallic charge materials Finshing of raw castings Melt operations Melt preparation Melt treatment devices Control and regulation technology Environment protection and disposal Dross recovery Gussteile

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19

Arbeitsschutz und Ergonomie Feuerfesttechnik Förder- und Lagertechnik Form- und Kernherstellung Formzubehör, Hilfsmittel Gießereianlagen Gießmaschinen und Gießeinrichtungen Handhabungstechnik Konstruktion und Design Messtechnik und Materialprüfung Metallische Einsatzstoffe Rohgussnachbehandlung Schmelzbetrieb Schmelzvorbereitung Schmelzebehandlungseinrichtungen Steuerungs- und Regelungstechnik Umweltschutz und Entsorgung Schlackenrückgewinnung Cast parts

4.2 Heat-resistent technology

4.6 Foundry equipment

 Refractories

 Casting machines

Feuerfesttechnik

Feuerfeststoffe

promat GmbH – Techn. Wärmedämmung Scheifenkamp 16, D-40878 Ratingen Tel. +49 (0) 2102 / 493-0, Fax -493 115 [email protected], www.promat.de

Gießereianlagen

Gießmaschinen

see Equipment and accessories 3.1

4.3 Conveyor and storage technology

SeCO/WArWICk S.A. see Heat treatment 2.4

4.7 Casting machines and equipment

Gießereimaschinen und Gießeinrichtungen

www.mechatherm.com see Smelting technology 1.5

Förder- und Lagertechnik

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5 Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

4.5 Mold accessories and accessory materials

 Heat treatment furnaces Wärmebehandlungsöfen

see Foundry equipment 4.6

Molten Metall Level Control

Ostra Hamnen 7 SE-430 91 Hono / Schweden Tel.: +46 31 764 5520, Fax: +46 31 764 5529 E-Mail: [email protected] Internet: www.precimeter.com Sales contact: Jan Strömbeck

Formzubehör, Hilfmittel

 Fluxes

Wagstaff, Inc.

Flussmittel

Solvay Fluor GmbH Hans-Böckler-Allee 20 D-30173 Hannover Telefon +49 (0) 511 / 857-0 Telefax +49 (0) 511 / 857-2146 Internet: www.solvay-fluor.de

www.alu-web.de

ALUMINIUM · 3/2010

see Billet Heating Furnaces 2.1

 Solution annealing furnaces/plant Lösungsglühöfen/anlagen

ernST reInHArdT GMBH Postfach 1880, D-78008 VS-Villingen Tel. 07721/8441-0, Fax 8441-44 E-Mail: [email protected] Internet: www.Ernst-Reinhardt.com

see Casting machines 1.6

 Mould parting agents Kokillentrennmittel

Schröder kG Schmierstofftechnik Postfach 1170 D-57251 Freudenberg Tel. 02734/7071 Fax 02734/20784 www.schroeder-schmierstoffe.de

77

Lieferverzeichnis

4.8 Handling technology Handhabungstechnik

Vollert Anlagenbau GmbH + Co. kG see Packaging equipment 2.3

TrIMeT ALuMInIuM AG niederlassung Gelsenkirchen Am Stadthafen 51-65 D-45681 Gelsenkirchen Tel.: +49 (0) 209 / 94089-0 Fax: +49 (0) 209 / 94089-60 Internet: www.trimet.de

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

 Manipulators Manipulatoren

see Equipment and accessories 3.1

SerMAS InduSTrIe E-Mail: [email protected] See Casting Machines 1.6

4.9 Construction and Design

Konstruktion und Design

THERMCON OVENS BV

see Extrusion 2

TrIMeT ALuMInIuM AG niederlassung Harzgerode Aluminiumallee 1 06493 Harzgerode Tel.: 039484 / 50-0 Fax: 039484 / 50-100 Internet: www.trimet.de

4.13 Melt operations Schmelzbetrieb

4.11 Metallic charge materials

www.mechatherm.com see Smelting technology 1.5

 Aluminium alloys

 Heat treatment furnaces

Metallische Einsatzstoffe

Aluminiumlegierungen

Wärmebehandlungsanlagen

see Billet Heating Furnaces 2.1

 Pre alloys / Vorlegierungen

 Recycling / Recycling

Chr. Otto Pape GmbH

Metalle Berliner Allee 34 D-30855 Langenhagen Tel:+49(0)511 786 32-0 Fax: -32 Internet: www.papemetals.com E-Mail: [email protected]

78

SeCO/WArWICk S.A. see Heat treatment 2.4

 Holding furnaces Warmhalteöfen

MeTALLHAndeLSGeSeLLSCHAFT SCHOOF & HASLACHer MBH & CO. kG Postfach 600714, D 81207 München Telefon 089/829133-0 Telefax 089/8201154 E-Mail: [email protected] Internet: www.metallhandelsgesellschaft.de

MeTALLHAndeLSGeSeLLSCHAFT SCHOOF & HASLACHer MBH & CO. kG Postfach 600714, D 81207 München Telefon 089/829133-0 Telefax 089/8201154 E-Mail: [email protected] Internet: www.metallhandelsgesellschaft.de

MArx GmbH & Co. kG Lilienthalstr. 6-18 D-58638 Iserhohn Tel.: +49 (0) 2371 / 2105-0, Fax: -11 E-Mail: [email protected] Internet: www.marx-gmbh.de

 Melting furnaces Schmelzöfen

Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-43 Fax: +49 (0) 211 / 50 13 97 E-Mail: [email protected] Internet: www.bloomeng.com Sales Contact: Klaus Rixen

Gautschi engineering GmbH see Casting equipment 3.1

Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-43 Fax: +49 (0) 211 / 50 13 97 E-Mail: [email protected] Internet: www.bloomeng.com Sales Contact: Klaus Rixen Gautschi engineering GmbH see Casting equipment 3.1

see Equipment and accessories 3.1

SeCO/WArWICk S.A. see Heat treatment 2.4

ALUMINIUM · 3/2010

Lieferverzeichnis

 Heat treatment furnaces Wärmebehandlungsanlagen

Gautschi engineering GmbH see Casting equipment 3.1

4.15 Melt treatment devices Schmelzbehandlungseinrichtungen

Metaullics Systems europe B.V. Ebweg 14 NL-2991 LT Barendrecht Tel. +31-180/590890 Fax +31-180/551040 E-Mail: [email protected] Internet: www.metaullics.com

4.17 Environment protection and disposal Umweltschutz und Entsorgung

 Dust removal / Entstaubung neOTeCHnIk GmbH Entstaubungsanlagen Postfach 110261, D-33662 Bielefeld Tel. 05205/7503-0, Fax 05205/7503-77 [email protected], www.neotechnik.com

HerTWICH enGIneerInG GmbH see Casthouse (foundry) 1.5

4.16 Control and regulation technology Steuerungs- und Regelungstechnik

see Equipment and accessories 3.1

 Flue gas cleaning Rauchgasreinigung

 HCL measurements HCL Messungen

SeCO/WArWICk S.A. see Heat treatment 2.4

4.14 Melt preparation

Schmelzvorbereitung

Ceraflux India pvt. Ltd. F - 59 & 60, MIDC, Gokul Shirgaon, Kolhapur - 416 234. Maharastra (India) E-Mail: [email protected] [email protected] Web: www.ceraflux.com

OpSIS AB Box 244, S-24402 Furulund, Schweden Tel. +46 (0) 46-72 25 00, Fax -72 25 01 E-Mail: [email protected] Internet: www.opsis.se

do you need more information? E-Mail: [email protected]

 Degassing, filtration

dantherm Filtration GmbH Industriestr. 9, D-77948 Friesenheim Tel.: +49 (0) 7821 / 966-0, Fax: - 966-245 E-Mail: [email protected] Internet: www.danthermfiltration.com

4.19 Cast parts / Gussteile

TrIMeT ALuMInIuM AG niederlassung Harzgerode Aluminiumallee 1 06493 Harzgerode Tel.: 039484 / 50-0 Fax: 039484 / 50-100 Internet: www.trimet.de

Entgasung, Filtration

drache umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: http://www.drache-gmbh.de Gautschi engineering GmbH see Casting equipment 3.1

5

Materials and Recycling Werkstoffe und Recycling

 Granulated aluminium Aluminiumgranulate

Chr. Otto Pape GmbH  Melt treatment agents

Schmelzebehandlungsmittel

Gautschi engineering GmbH see Casting equipment 3.1

ALUMINIUM · 3/2010

Aluminiumgranulate Berliner Allee 34 D-30855 Langenhagen Tel:+49(0)511 786 32-0 Fax: -32 Internet: www.papemetals.com E-Mail: [email protected]

eCkA Granulate Austria GmbH Bürmooser Landesstraße 19 A-5113 St. Georgen/Salzburg Telefon +43 6272 2919-12 Telefax +43 6272 8439 Kontakt: Ditmar Klein E-Mail: [email protected]

79

Lieferverzeichnis

6

Machining and Application Bearbeitung und Anwendung

6.3 Equipment for forging and impact extrusion Ausrüstung für Schmiedeund Fließpresstechnik

 Hydraulic Presses

Hydraulische Pressen

6.1 Surface treatment processes

Prozesse für die Oberflächenbehandlung

 Cleaning / Reinigung

Henkel AG & Co. kGaA

siehe Prozesse für die Oberflächentechnik 6.1

LASCO umformtechnik GmbH Hahnweg 139, D-96450 Coburg Tel. +49 (0) 9561 642-0 Fax +49 (0) 9561 642-333 E-Mail: [email protected] Internet: www.lasco.com

 Joining / Fügen

Henkel AG & Co. kGaA

siehe Prozesse für die Oberflächentechnik 6.1

Henkel AG & Co. kGaA D-40191 Düsseldorf Tel. +49 (0) 211 / 797-30 00 Fax +49 (0) 211 / 798-23 23 Internet: www.henkel-technologies.com

 Pretreatment before coating

Vorbehandlung vor der Beschichtung

Henkel AG & Co. kGaA

siehe Prozesse für die Oberflächentechnik 6.1

 Adhesive bonding / Verkleben

Henkel AG & Co. kGaA

siehe Prozesse für die Oberflächentechnik 6.1

6.2 Semi products Halbzeuge

8

Literature Literatur

 Technikcal literature Fachliteratur

Taschenbuch des Metallhandels Fundamentals of extrusion Technology Giesel Verlag GmbH Verlag für Fachmedien Rehkamp 3 · 30916 Isernhagen Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157 Internet: www.alu-bookshop.de.

 Wires / Drähte

 Anodising / Anodisation

Henkel AG & Co. kGaA

siehe Prozesse für die Oberflächentechnik 6.1

drAHTWerk eLISenTAL W. erdmann GmbH & Co. Werdohler Str. 40, D-58809 Neuenrade Postfach 12 60, D-58804 Neuenrade Tel. +49(0)2392/697-0, Fax 49(0)2392/62044 E-Mail: [email protected] Internet: www.elisental.de

Could not find your „keywords“? please ask for our complete „Supply sources for the aluminium industry“. Telefon: 0511/7304-148 Beate Schaefer 80

 Technical journals Fachzeitschriften

Giesel Verlag GmbH Verlag für Fachmedien Rehkamp 3 · 30916 Isernhagen Tel. 0511 / 73 04-122 · Fax 0511 / 73 04-157

ALUMINIUM · 3/2010

IMPRESSUM / IMPRINT

International

ALUMINIUM Journal 86. Jahrgang 1.1.2010 Redaktion / Editorial office Dipl.-Vw. Volker Karow Chefredakteur, Editor in Chief Franz-Meyers-Str. 16, 53340 Meckenheim Tel: +49(0)2225 8359 643 Fax: +49(0)2225 18458 E-Mail: [email protected] Dipl.-Ing. Rudolf P. Pawlek Fax: +41 274 555 926 Hüttenindustrie und Recycling Dipl.-Ing. Bernhard Rieth Walzwerkstechnik und Bandverarbeitung Verlag / Publishing house Giesel Verlag GmbH, Verlag für Fachmedien, Postfach 120158, 30907 Isernhagen; Rehkamp 3, 30916 Isernhagen, Tel: 0511/7304-0, Fax: 0511/7304-157. E-mail: [email protected] Internet: www.alu-web.de. Postbank/postal cheque account Hannover, BLZ/routing code: 25010030; Kto.Nr./ account no. 90898-306, Bankkonto/ bank account Commerzbank AG, BLZ/ routing code: 25040066, Kto.-Nr./account no. 1500222 Geschäftsleitung / Managing Director Klaus Krause Anzeigendisposition / Advertising layout Beate Schaefer Tel: 05 11/ 73 04-148 E-Mail: [email protected] Vertriebsleitung / General Manager Distribution Jutta Illhardt Tel: 05 11/ 73 04-126 E-Mail: [email protected] Abonnenten-Service / Reader service Sabrina Matzat Tel: 05 11/73 04-125 E-Mail: [email protected] Herstellung & Druck / Printing house BWH GmbH, Beckstr. 10 D-30457 Hannover Jahresbezugspreis EUR 285,- (Inland inkl. 7% Mehrwertsteuer und Versandkosten). Europa EUR 289,- inkl. Versandkosten. Übersee US$ 375,- inkl. Normalpost; Luftpost zuzügl. US$ 82,-. Preise für Studenten auf Anfrage. ALUMINIUM erscheint zehnmal pro Jahr. Kündigungen jeweils sechs Wochen zum Ende der Bezugszeit. Subscription rates EUR 285.00 p.a. (domestic incl. V.A.T.) plus postage. Europe EUR 289.00 incl. surface mail. Outside Europe US$ 375.00 incl. surface mail, air mail plus US$ 82.00. ALUMINIUM is published monthly (10 issues a year). Cancellations six weeks prior to the end of a year. Anzeigenpreise / Advertisement rates Preisliste Nr. 50 vom 1.1.2010. Price list No. 50 from 1.1.2010.

ALUMINIUM · 3/2010

Die Zeitschrift und alle in ihr enthaltenen Beiträge und Abbildungen sind urheberrechtlich geschützt. Jede Verwertung außerhalb der engen Grenzen des Urheberrechtsgesetzes ist ohne Zustimmung des Verlages unzulässig und strafbar. Das gilt insbesondere für Vervielfältigungen, Übersetzungen, Mikroverfilmungen und die Einspeicherung und Bearbeitung in elektronischen Systemen. Der Verlag übernimmt keine Gewähr für die Richtigkeit der in diesem Heft mitgeteilten Informationen und haftet nicht für abgeleitete Folgen. Haftung bei Leistungsminderung durch höhere Gewalt oder andere vom Verlag nicht verschuldete Umstände (z. B. Streik) ist ausgeschlossen. This journal and all contributions contained therein are protected by copyright. Any utilization outside the strict limits of copyright legislation without the express consent of the publisher ist prohibited and actionable at law. This applies in particular to reproduction, translations, microfilming and storage or processing in electronic systems. The publisher offers no guarantee that the information in this volume is accurate and accepts no liability for consequences deriving therefrom. No liability whatsoever is accepted for perfomance lag caused by force majeure or by circumstances beyond the publisher’s control (e.g. industrial action). ISSN: 0002-6689 © Giesel Verlag GmbH Verlagsrepräsentanz / Representatives Nielsen-Gebiet 1 (Schleswig-Holstein, Hamburg, Bremen, Niedersachsen außer Raum Osnabrück): Giesel Verlag GmbH, Dennis Roß Büro Augsburg: Bräuergäßchen 6, 86150 Augsburg Tel: 0821/319 880-34, Fax: 0821-319880-80 E-Mail: [email protected] www.giesel-verlag.de Nielsen-Gebiet 2 (Nordrhein-Westfalen, Raum Osnabrück): Medienbüro Jürgen Wickenhöfer Minkelsches Feld 39, 46499 Hamminkeln Tel: 0 28 52 / 9 4180 Fax: 0 28 52 / 9 4181 E-Mail: [email protected] www.jwmedien.de Nielsen-Gebiet 3a (Hessen, Saarland, Rheinland-Pfalz): multilexa GmbH, publisher services Linsenhofer Straße 51, 98529 Suhl Tel: 03681/4550478 Fax: 03681/4553042 E-Mail: [email protected] www.multilexa.com Nielsen-Gebiet 3 b (Baden-Württemberg): G. Fahr, Verlags- und Pressebüro e. K. Marktplatz 10, 72654 Neckartenzlingen Tel: 0 71 27/30 84 Fax: 07127/2 14 78 E-Mail: [email protected] Nielsen-Gebiet 4 (Bayern): G. Fahr, Verlags- und Pressebüro e.K. Marktplatz 10, 72654 Neckartenzlingen Tel: 0 8362/5054990 Fax: 08362/5054992 E-Mail: [email protected]

Nielsen-Gebiet 5, 6 + 7 (Berlin, Mecklenburg-Vorpommern, Brandenburg, Sachsen-Anhalt Sachsen, Thüringen): multilexa GmbH, publisher services Linsenhofer Straße 51, 98529 Suhl Tel: 03681/4550478 Fax: 03681/4553042 E-Mail: [email protected] www.multilexa.com Scandinavia, Denmark, Netherlands, Belgium, Luxembourg multilexa GmbH, publisher services Linsenhofer Straße 51, 98529 Suhl, Germany Tel: +49 (0)3681/4550478 Fax: +49 (0)3681/4553042 E-Mail: [email protected] www.multilexa.com Switzerland JORDI PUBLIPRESS Postfach 154, CH-3427 Utzenstorf Tel. +41 (0)32 666 30 90, Fax +41 (0)32 666 30 99 E-Mail: [email protected] www.jordipublipress.ch Austria Verlagsbüro Michaela Wotawa Sonnenweg 83, A-1140 Wien Tel: +43(0)699 10455027 Fax: +43(0)1 9 792971 E-Mail: [email protected] Italy MEDIAPOINT & COMMUNICATIONS SRL Corte Lambruschini – Corso Buenos Aires, 8 Vo piano – Interno 7, I-16129 Genova Tel: +39(0)10 5 70 49 48, Fax: +39(0)10 5 53 00 88 E-Mail: [email protected] www.mediapointsrl.it USA, Canada, Africa, GCC countries etc. Marketing Xpertise Rieth Dipl.-Ing. Bernhard Rieth Strümper Berg 10, D-40670 Meerbusch Tel: +49 (0)2159 962 643 Fax: +49 (0)2159 962 644 E-Mail: [email protected] United Kingdom Marketing Xpertise Rieth Dipl.-Ing. Bernhard Rieth Strümper Berg 10, D-40670 Meerbusch Tel: +49 (0)2159 962 643 Fax: +49 (0)2159 962 644 E-Mail: [email protected] France DEF & Communication Axelle Chrismann 48 boulevard Jean Jaurès F-92110 Clichy Tel: +33 (0)1 47 30 71 80, Fax: +33 (0)1 47 30 01 89 E-Mail: [email protected]

Der ALUMINIUM-Branchentreff des Giesel Verlages: www.alu-web.de

81

VORSCHAU / PREVIEW

IM NÄCHSTEN HEFT

IN THE NEXT ISSUE

Special: Die internationale Strangpressindustrie

Special: The international extrusion industry

Maschinen und Anlagen, Technologien, Projekte. Geplante Beiträge, unter anderem: • Wettbewerb in der Strangpressindustrie – Analyse unterschiedlicher Geschäftsmodelle • Möglichkeiten zur Verbesserung der Energiekostenund CO2-Bilanz bei Bolzenerwärmungsanlagen • Unternehmensporträt GIA Clecim Press

Wirtschaft

Machines and plants, technologies and projects. Subjects, among others: • Competing in aluminium extrusions – a normative analysis exploring alternative business models • Ways to improve energy costs and the CO2 balance of billet heaters • GIA Clecim Press – a company portrait • Composite extrusion and threading of continuously reinforced aluminium profiles

Research

• Der deutsche und europäische Halbzeugmarkt

• Hot profile extrusion of different chip types of aluminium alloy 6060

Sonstiges • Kunst in Aluminium, Arbeiten des Künstlerehepaars Heike Rose und Bernd W. Schmidt-Pfeil

Erscheinungstermin: Anzeigenschluss: Redaktionsschluss:

Other topics • Latest international news from the industry

Date of publication: Advertisement deadline: Editorial deadline:

02. April 2010 19. März 2010 15. März 2010

02 April 2010 19 März 2010 15 März 2010

Abonnement-Bestellung

Subscription-Order

❒ Ja, wir möchten die Zeitschrift ALUMINIUM ab sofort zum Jahresbezugspreis von EUR 285,- inkl. Mehrwertsteuer (Ausland EUR 289,-) und Versandkosten abonnieren. Das Magazin erscheint zehn Mal pro Jahr. Das Abonnement kann mit einer sechswöchigen Frist zum Bezugsjahresende gekündigt werden.

❒ Yes, we want to subscribe to ALUMINIUM. The rate is EUR 289.00 per year incl. postage. Outside Europe US$ 375.00 incl. surface mail, air mail plus US$ 82.00 The magazine is published ten times a year. Cancellations six weeks prior to the end of a subscription year.

Name / name Firma / company Anschrift / address

Umsatzsteuer-Ident.-Nr. / VAT Reg.-No. Datum / date

Unterschrift/Signature

Fax: +49 (0) 511 73 04 157

82

ALUMINIUM · 3/2010

official fair newspapers for

The

" 
!


 
&


"#





&
  
"!


&
$


&


 #"
 "#


 
&
# #


%#



+

+  .

 .   % 
% 




.   . ' ' %"&")%
  )% $
$)  
$ 

Are you exhibiting at ALUMINIUM in Essen?

A @ )@
A 

. < AA






% 
! %
( % 
 
( %' &"/
01"%1
"

%% &
   

 %
 &
 
 &+
:201"


"
" 8@A @

)& %
! /1"51
!"/
)"! ! 
 %%!
 72
!  A?@ 
8AA

9A
8 ;
 
!& "&+
:2 A
&$  '
*

>
@A 01"/1"51 &"+1
!&"
-1&(
%  
+8@

8AA

> @

-&/(2 )*0&1 5**556421,0 ).1.1&+24 *6&/5 1*:6 

 

  
 








A

8@8 88@
'8  


& @
 8@  

 @
9  :
   
 9@<
;@
:
# 
 A
@8@  : A @
:
:8 @>
< 


:B 9  :
)8
@
 
# ; @8A ;;
:

: