INDUSTRY NEWS
MINING & REFINING
SUSTAINABLE ALUMINIUM
EVENT PREVIEWS
www.aluminiumtoday.com March/April 2022—Vol.35 No.2
THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING
A LU M I N I U M I N T E R N AT I O N A L TO DAY M A R C H /A P R I L 2 0 2 2 V O L . 3 5 N O 2
JE
ALUMINIUM EXTRUSION DIE TEL: + 86 512 57669158 /+86 13962662780 Email: jihaneen@163.com / jihaneen@hotmail.com Web: www.jihaneen.com
AIT march april with silver logo.indd 1
01/03/2022 09:54:23
Wisdom Comes With Longevity. Like the great Redwoods of California, we’ve been around a while too. With decades of experience, comes a certain wisdom. However, we never stop learning. We strive to always offer the very best solutions for very specific situations.
MarchAprild22 ad.indd 1
|
gcinfo@grancoclark.com
|
www.grancoclark.com
M
+1-800-918-2600
AD
E
IN
US
A
Come collaborate with us at ET22 Booth 401.
2/3/22 8:43 AM
CONTENTS 1
www.aluminiumtoday.com
Volume 35 No. 2 – March/April 2022
COVER
Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com
INDUSTRY NEWS
MINING & REFINING
SUSTAINABLE ALUMINIUM
Editorial Assistant: Zahra Awan Tel: +44 (0) 1737 855038 zahraawan@quartzltd.com
2
LEADER
2
NEWS
EVENT PREVIEWS
www.aluminiumtoday.com March/April 2022—Vol.35 No.2
THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING
Production Editor: Annie Baker
HARRIS DISTILLERY
Sales
Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117
A LU M I N I U M I N T E R N AT I O N A L TO DAY M A R C H /A P R I L 2 0 2 2 V O L . 3 5 N O 2
Commercial Sales Director: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0)1737 855027
6
Aluminium lies at the heart of the Isle of Harris
THE ALUMINA CHRONICLES
Advertisement Production Production Executive: Martin Lawrence
11
Managing Director: Tony Crinion CEO: Steve Diprose
Aluminium Industry in Guinea
JE
ALUMINIUM EXTRUSION DIE
Circulation/subscriptions Jack Homewood Tel +44 (0) 1737 855028 Fax +44 (0) 1737 855034 email subscriptions@quartzltd.com Annual subscription: UK £257, all other countries £278. For two year subscription: UK £485, all other countries £501. Airmail prices on request. Single copies £47
TEL: + 86 512 57669158 /+86 13962662780 Email: jihaneen@163.com / jihaneen@hotmail.com Web: www.jihaneen.com
AIT march april with silver logo.indd 1
MINING & REFINING
01/03/2022 09:54:23
Cover picture courtesy of Kunshan Jihan Een Enterprise Co., Ltd.
6
11
18
Australia’s Bauxite and Alumina Industries Partnering to reduce emissions through technology
Supporters of Aluminium International Today
22
A closer look at Metro Mining
25
High Purity Alumina - Another way aluminium is part of the clean energy
22
revolution 28
Renewable hydrogen could reduce emissions in alumina refining
29 ALUMINIUM INTERNATIONAL TODAY is published six times a year by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, UK. Tel: +44 (0) 1737 855000 Fax: +44 (0) 1737 855034 Email: aluminium@quartzltd.com Aluminium International Today (USO No; 022-344) is published bi-monthly by Quartz Business Ltd and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Aluminium International c/o PO Box 437, Emigsville, PA 17318-0437. Printed in the UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent, NP12 2YA, UK © Quartz Business Media Ltd 2022
35
44
Solving the descaling dilemma: Robotic Arms
SUSTAINABLE ALUMINIUM 33
Decarbonising aluminium products
35
Hydro in the USA: A journey towards sustainability
40
Why education is key to building consumer confidence in recycling
SEARCH FOR ALUMINIUM INTERNATIONAL TODAY
INDUSTRY EVENTS 44
ALUMINIUM 2022
47
Metef 2022
ISSN1475-455X
Aluminium International Today
Contents Template.indd 1
March/April 2022
03/03/2022 10:33:23
2 COMMENT
TOP STORIES
Hydro invests in carbon capture company Verdox
Anyone who knows me, knows I am not usually stuck for words, but trying to write this month’s column has left me staring at a blank screen and avoiding looking at the live BBC News feed that keeps updating in the corner. These days, the world feels like a smaller place. Travel (when we can) makes even the furthest corners of the world accessible. We are inundated with news on a regular basis, meaning our senses are constantly being heightened and our appetite to either know more or try to switch off is tested. Even within the aluminium sector, we are working to ensure that news coverage is regular and delivered in a way that is user-friendly for all readers. Hopefully you will have seen our new weekly news video roundups and we have also recently launched two dedicated Greener Aluminium and Future Aluminium newsletters to provide specific content on sustainable and digital manufacturing projects. As well as the latest news, this issue also includes a big feature on Mining & Refining. Special thanks goes to Marghanita Johnson, Chief Executive Officer, Australian Aluminium Council, for her contribution with a selection of interesting articles, highlighting that Australian bauxite and alumina will help meet global demand for aluminium. We also hear from Hans Erik Vatne, SVP, Chief Technology Officer, Hydro, about how the company is working to decarbonise its products. I hope you enjoy the issue. nadinebloxsome@quartzltd.com
March/April 2022
Nadine News.indd 1
Hydro is investing USD 20 million in U.S. company Verdox, a Massachusetts Institute of Technology (MIT) spin-off, commercialising an all-electric carbon removal technology applicable both for capturing emissions from aluminium production and directly from air. “A key part of our sustainability ambitions is to reduce emissions from our aluminium smelters. Hydro is well placed to be an active
shareholder and contribute competence and experience that will add value to Verdox. The cooperation will speed up the decarbonisation of our smelters,” says Eivind Kallevik, Executive Vice President of Aluminium Metal in Hydro. Hydro and Verdox entered into a collaboration in early 2021. The technology has been tested to assess its applicability to capturing
the CO2 in the off gas of Hydro’s primary aluminium smelter technology, and early results are very promising. The next phase of collaboration includes testing and piloting of the technology at Hydro’s aluminium smelters with the goal of reaching industrial scale by 2030. Following the USD 20 million investment, Hydro will have a minority ownership position.
EGA to build first aluminium recycling facility in the UAE Emirates Global Aluminium (EGA) has announced the company plans to build a 150,000 tonnes per year aluminium recycling facility, thecompany’s first and set to be the largest in the UAE. EGA intends to market recycled aluminium under the product name EternAL. The facility will process post-consumer aluminium scrap such as used window frames, as well as pre- consumer aluminium scrapfrom extrusion production, into low-carbon, high quality aluminium billets. Aluminium scrap for the recy-
cling facility will mainly be sourced from the UAE and the wider region. More than half thealuminium scrap generated in the GCC is currently either disposed of or exported. Feasibility studies for the project are underway. Production rampup could begin as early as 2024. Abdulnasser Bin Kalban, Chief Executive Officer of EGA, said: “End users of aluminium – from auto manufacturers to beverage makers – are increasingly committing to net zero in response to the expectations of society. This, our first recycling facility at
EGA to produce EternAL, is one of the steps we plan to take to provide low carbon metal for our customers around the world.
Alba and Mitsubishi Heavy Industries Ink MoU for Carbon Capture Aluminium Bahrain B.S.C. (Alba) has inked a Memorandum of Understanding (MoU) with Mitsubishi Heavy Industries EMEA Ltd. (MHI EMEA), part of Mitsubishi Heavy Industries (MHI) Group, on 19 January 2022 to collaborate on opportunities to reduce Alba’s carbon footprint. The MoU, first-of-its-kind, with
an aluminium producer – will lay the foundations to conduct a feasibility study on utilising the technology to capture CO2 from flue gas, developed by MHI Group in collaboration with Kansai Electric Power Co., to reduce Alba’s plant emissions for decarbonisation. Speaking on this occasion, Alba’s Chairman of the Board Shaikh
Daij bin Salman bin Daij Al Khalifa said: “Environment, Social and Governance (ESG) matters are fronting everything we do in Alba. This MoU will play a fundamental role as we want to be accelerators and embed sustainability considerations in our operations to be more environmentally responsible and inclusive.” Aluminium International Today
01/03/2022 15:32:08
NEWS 3
Speira to acquire and integrate Real Alloy Speira has announced that it has signed a definitive agreement to acquire the European business (“Real Alloy Europe”) of Real Alloy. Completion of the transaction is subject to customary closing conditions and approvals. Speira claims customers will benefit from more high-quality products with a low carbon footprint. As part of Speira, Real Alloy Europe will continue to provide significant third-party recycling services to the European aluminium industry. Real Alloy Europe is a leading
European recycler of aluminium and magnesium scrap and related by products, with seven facilities and approximately 600 employees across Germany, Norway, France and the United Kingdom. The acquisition will enhance Speira’s ability to utilise recycled metal in its production and deliver high-quality, low carbon rolled aluminium products to its customers. Speira CEO Einar Glomnes said, “The integration of Real Alloy Europe into Speira will accelerate our strategy of creating closed loops
APPOINTMENTS
from scrap to final product and back. We look forward to investing further in Speira’s and Real Alloy Europe’s combined capabilities to meet the market’s demand for sustainable and circular solutions.” “Following the acquisition, Speira will continue to focus on delivering third-party recycling services to existing and new customers of Real Alloy Europe. We will be serving the whole European aluminium industry, working closely with customers across the value chain”, said Glomnes.
HAI: New melting furnace at Santana site into operation Hammerer Aluminum Industries (HAI) has invested EUR 4.5 million in a third melting furnace for recycling material for the casting at the Romanian site in Santana. Since the beginning of 2022, the new melting furnace has ensured a significant increase in capacity. This increases the recycling and remelting capacity of the HAI Group to 250,000 tons per year. HAI reacted to the high demand for aluminium lightweight products by investing in a third recycling furnace at the Santana site.
The investment in a multi-chamber furnace for recycling material is an important development step for the HAI Group due to the high demand for aluminium lightweight products. “We were able to implement the project quickly and put the melting furnace into operation at the beginning of the year as planned. This means that we can now supply the market with high-quality recycling material at full capacity,” said HAI CEO, Rob van Gils.
Novelis to build $365 million recycling centre Novelis Inc. has announced it will invest $365 million to build a highly advanced recycling centre for automotive in North America. With an annual casting capacity of 240 kt of sheet ingot, the facility is expected to reduce the company’s carbon emissions by more than one million tons each year. The new recycling facility will be built adjacent to Novelis’ existing automotive finishing plant in Guthrie, Kentucky. The centre will enable Novelis
to grow its closed-loop-recycling programs with more automotive customers in North America. Through closed-loop recycling, the company takes back the aluminium remaining after automotive parts are stamped from sheets and remakes it into the same product for new vehicle production. The centre will also have the capability to process aluminium from vehicles at the end of their lifecycle. Using recycled aluminium as input
material requires only 5% of the energy used to make primary aluminium, thus avoiding 95% of the carbon emissions associated with production. The centre will be equipped with advanced shredding and sorting technology, as well as energy-efficient innovations to support the company’s sustainability goal to reduce energy intensity by 10% by 2026. Ground-breaking is scheduled for early 2022.
EGA Retirement of GLAFRI’s Director General, Stefan Glimm
After serving the aluminium foil industry for 30 years – and the aluminium industry in general for almost four decades – Stefan Glimm has announced his retirement and will step down from his remaining responsibility as Director General of the Global Aluminium Foil Roller Initiative (GLAFRI) end of February 2022. GLAFRI President Göksal Güngör comments: “On behalf of our members and board, I thank Stefan for his leadership, tireless work and great contributions over the years to GLAFRI and the aluminium foil industry!”
European Aluminium Welcomes New Director General Paul Voss
European Aluminium has announced the appointment of Paul Voss as Director General, with effect on 1 February. Mr. Voss will succeed Gerd Götz, who is retiring at the end of March after nearly a decade at the helm of the Association. Paul Voss joins European Aluminium from Euroheat & Power, the association for the European district energy sector, wherehe acted as Managing Director for the past eight years. Mr. Voss is a long-term public affairs and governmental relationsexpert with 20 years of experience in the Brussels and energy sector. Paul Voss has studied in Canada, France and Belgium and holds a master’s degree in European Public Policy.
March/April 2022
Nadine News.indd 2
01/03/2022 15:32:27
4 NEWS
www.aluminiumtoday.com
Global Aluminium Associations call on G7 trade ministers to tackle state subsidies The Aluminum Association, European Aluminium, the Aluminium Association of Canada and the Japan Aluminium Association jointly released their newest policy-maker briefing, Towards a Fairer and Cleaner Trade in Aluminium, on the ongoing challenges in the global trade of aluminium. The paper cites data from the Organization for Economic Co-operation and Development (OECD) demonstrating how mas-
sive state subsidies, especially in China, have distorted aluminium supply chains and harmed the environment. The briefing was shared with lead trade ministers in all G7 nations (Canada, France, Germany, Italy, Japan, the United Kingdom and the United States). “With continued demand growth and U.S. investment totaling $4 billion in the over the past decade, American aluminium has an enormous opportunity to
thrive in the 2020s and beyond,” said Charles Johnson, president & CEO of the Aluminum Association. “But, meeting our full potential will require smart policy to combat massive state subsidies that distort global supply chains and slow down the industry’s push to decarbonize. Aluminium firms everywhere – not just state-owned enterprises – should benefit from demand that is expected to grow 80% globally by 2050.”
ASI certifies ALVANCE British Aluminium ALVANCE British Aluminium has achieved ASI Performance Standard certification with Provisional status for its smelting and casting operation at Lochaber, Scotland. Aluminium slab products from Lochaber, Britain’s only smelter, supply multiple downstream sectors in the UK and Europe, and have a low carbon footprint as the plant is powered by hydroelectricity. “The ASI certification is considered to be the gold standard for sustainable production in the
industry and I’m delighted that the Lochaber Smelter’s operations have been recognised in this way. We are committed to delivering a market-leading low-carbon product and the ASI certification will give confidence to aluminium customers looking to demonstrate
sustainable supply chains. Lochaber is emblematic of ALVANCE’s GREENALUMINIUM vision – we produce high value, low-carbon, essential metal using renewable energy. The ASI accreditation is an acknowledgement of the work each and every member of our staff do every day to deliver on our sustainability ambitions – this certification belongs to them and I’m very proud of their achievement,” said Tom Uppington, Managing Director of ALVANCE British Aluminium.
Hazelett joins EBNER Group Hazelett Strip-Casting Corporation of Colchester has announced that it has become a member of the EBNER Group through the acquisition by EBNER . The EBNER Group consists of EBNER Industrieofenbau in Leonding, Austria, EBNER Furnaces in Wadsworth, USA, EBNER Industrial Furnaces in Taicang, China, Gautschi Engineering in Ran-
shofen, Austria, HPI in Ranshofen, Austria, GNA alutech in Montreal, Canada, and EED in Taicang, China. Together the companies offer a wide range of furnace facilities, upstream and downstream auxiliary equipment, project management and services to the aluminium, steel and copper base metals sectors. Together with Mino, the EBNER
Group will be able to offer complete process lines to the aluminium flat rolled products industry featuring Hazelett twin-belt continuous casting technology. Hazelett technology is used in metal manufacturing processes worldwide to cast aluminium, copper, zinc, and lead into metal strip and bar used to create countless products.
2022 DIARY May 3rd - 5th ET 2022 The Aluminum Extruders Council (AEC) and the ET Foundation have announced the rescheduled dates and location for the Twelfth International Aluminum Extrusion Technology Seminar, previously postponed due to the coronavirus pandemic. Held in Florida, USA www.ET-21.org 18 - 19th CRU 27th World Aluminium Conference. Held again in London for the first time since 2019. www.events.crugroup/ aluminium 24th Greener Aluminium Online Summit This Online Summit will bring together aluminium manufacturers and environmental solutions providers to discuss how the industry must continue to adapt, minimising the impacts associated with production of the metal today, while also developing technological pathways for the future. www.aluminiumtoday.com/ greener-aluminium
June 7th - 9th Harbor’s 14th Aluminium Summit The 14th Harbor Aluminium Summit offers the opportunity of networking with +700 metal suppliers, clients, brokers & industry players and connecting with decision makers from +360 companies across the value chain. Held in Chicago, USA. www.harboraluminumsummit. com 28th - 29th Sustainable Industrial Manufacturing (SIM) Europe Hosting leaders from the worlds of science, innovation, government, industry, and investment, SIM Europe will provide an opportunity for those at the frontier of energy intensive industrial manufacturing to collaborate and deliver real change. Held in Brussels, Belgium www.sustainableindustrial manufacturing.com For a full listing visit www.aluminiumtoday.com/ events Aluminium International Today
Nadine News.indd 3
01/03/2022 15:32:34
6 HARRIS DISTILLERY
Aluminium lies at the heart of the Isle of Harris The Isle of Harris Distillery launched a recycling programme integrating aluminium bottles into their brand. Zahra Awan* spoke with the distillery on the decision behind their choice of material and the response that the aluminium bottles have had from consumers. The first event I attended was the Aluminium Federation Briefing and Dinner in December 2021. It was there that I was introduced to the diversity of aluminium; it’s inspiring to see how Gin can be presented beautifully in aluminium. It’s
more inspiring to see what Gin can do to those in the Aluminium industry! The Isle of Harris Distillery provided the industry with the perfect example of why we, as a community, have struggled, searched and succeeded in providing
customers with accessible sustainable aluminium. The concept of a recycled, reusable aluminium bottle provided us all with a tangible product that we helped to create and could now use. A simple concept, but impactful.
*Editorial Assistant
March/April 2022
Distillery Harris.indd 1
Aluminium International Today
03/03/2022 07:37:06
HARRIS DISTILLERY 7
HISTORY OF THE DISTILLERY Isle of Harris Distillers Ltd, was formed in December 2007 and following finance being raised through private investors and development funding, building work began on a reclaimed piece of land at the head of East Loch Tarbert on March 2nd, 2014. In the face of wild island weather and the logistical challenges of building a distillery in the Outer Hebrides, building work was completed in late 2015 and the team of staff, drawn from the local community set about production of the island spirits and welcoming thousands of visitors. The vision of establishing the first distillery in the Isle of Harris was that of Anderson ‘Burr’ Bakewell, who has been deeply connected to the Island for many years. His vision was of a distillery built in the heart of Harris which would strive to be the source of local, social and economic growth, as well as a source of pride, expressed through the making of exemplary spirits. With the aim of creating something by, with and for the Isle of Harris.
What is The Refill Project? The Refill Project was created to address growing demand from customers to allow them to keep their treasured glass Isle of Harris Gin bottle instead of throwing it out. Although the glass bottle is fully recyclable, the beauty of the design seems to make it difficult for people to part with. So, the company is exploring the potential of new refill solutions and began by experimenting with aluminium as a high-quality material with exceptional recyclability, lightness, and excellent carbon footprint figures. At a smaller 500ml size, the new refill bottle is designed to top up your glass Isle of Harris Gin bottle before it is empty, so you never run out of your favourite island spirit again! The new refill bottle is only available through a limited annual subscription service initially, as the company tests the waters and evolve more ideas. Aluminium International Today
Distillery Harris.indd 2
What is the story behind choosing aluminium as the material to use for The Refill Project? The suggestion to return and reprocess bottles, wash and sanitise them, replace the labels and seals, and then ship them back across miles of land and sea again, made this popular proposal a very energy inefficient one. The team also looked at plastic pouches by post, but after many months of work to eliminate plastic from our business, and a couple of tough beach cleans, this felt like a backward step. The team eventually settled on using aluminium as our refill bottle material of choice, thanks to the advice from the team at UPM Raflatec, a world leader in sustainable labels and packaging materials.
March/April 2022
03/03/2022 07:38:41
8 HARRIS DISTILLERY
What has been the response to using aluminium and The Refill Project? The general response to using aluminium has been positive and encouraging. Here are a few quotes from locals of Isle of Harris in response to a survey we issued following The Refill Project. “I love the refill project’s genius way to cut down on waste and carbon footprint.” “I love the concept of more environmentally friendly packaging. I also do a lot of sailing and having a non-glass bottle that can get knocked about a bit more is also a massive attraction for me. With that said, my first aluminium bottle has been drained and is currently being used as a water bottle in my golf bag.” “We are delighted with our two refill packs received so far. Both have arrived perfectly and have been enjoyed, although I have to add that I am not keeping up with your gin-drinking schedule and have not finished them yet. I am so pleased to see the effort that you are making to ensure that the packets are environmentally sustainable and friendly and have learnt a lot about aluminium in the process.” With the multiple benefits of using aluminium, do you plan on furthering your venture and using aluminium in any other products? We will be assessing the project after the first year and look at ways of expanding the subscription offering or even selling the bottles individually. At the moment we use an off-the-shelf 500ml bottle but we’re keen to look at a bespoke 700ml bottle too. There are other ideas for using aluminium for pre-batched cocktails and tinctures in the longer term. With a strong community base, how has the company maintained its March/April 2022
Distillery Harris.indd 3
passion for recycling outside of the Distillery? We reuse draff, the primary barley byproduct of our whisky distilling to feed local livestock. Unlike many other distilleries we offer this for free in support of local crofters. The staff here are also keen to play their part in the local community and our second summer beach clean highlighted to us just how much plastic pollution affects even our remote shores. We have plans for more beach clean ups around the island in the coming year. We’re also collaborating with a local venture to promote e-bikes for staff, other locals and tourists. We will shortly install an electric charging point in our public car park, to encourage the use of electric vehicles. Are there any plans to further improve and promote the circular recyclability of the aluminium bottles that are sent out via the Refill Project? Each aluminium bottle sold comes with a flyer providing information on how to refill, recycle and repeat. This can also be found on our website – https:// harrisdistillery.com/pages/refill The crucial key to aluminium’s success is returning the bottles to the recycling bin so it can be reused over and over again. “So, as we celebrate this incredible material, always remember to let it go, and get it back into the loop to live another day!” What plans does the Isle of Harris Distillery have for its future endeavours into sustainability? Last year we commissioned an audit by Zero Waste Scotland to assess our energy use, and we’re currently implementing
some of their key recommendations. The first of these steps is investing substantially in upgrading our production area lighting system from halogen bulbs to more efficient LED equipment. We still have a long way to go to become a net-zero business and have much to do over the coming years to address the impact of our inevitable carbon emissions. For example, as an increasingly global business, we will need to look closely at the challenge of international shipping and examine the potential of carbon offsetting. Although we heat our public areas using air source pump technology and have a heat exchange system for production processes, our boilers run on less-thangreen kerosene. There are hopes that local Hydrogen projects may provide a cleaner solution for us in the long run, perhaps in combination with existing wind energy schemes and other island-based renewables. Even the seemingly simple matter of small-scale peat cutting to malt our barley will require scrutiny as we’re learning more from people like Peatland ACTION about best environmental practices for this age-old island tradition. The Harris Distillery was built with a longterm vision, something that would stand the tests of time, and bring sustainable success to our island community and the coming generations of Hearaich. With the success of our Refill Project, aluminium is definitely a material that we will be continuously looking at implementing in different areas of the business. And So… Here is the beginning of a tale where far up north from London, there is an Isle encouraging us all to pick up a sustainable bottle of Gin. � Aluminium International Today
03/03/2022 07:39:47
precimeter.com
5:1 125
40% more efficient than other high efficiency grain refiners Up to 90% less grain refiner needed 20% more cost savings Reduced particle count consistently increases melt quality Brings down fluoride emissions by two thirds +44 (0) 121 684 0175
MQP Alien Ad A4 AW.indd 1
| info@mqpltd.com
| www.mqpltd.com
01/02/2022 10:48
THE ALUMINA CHRONICLES 11
Aluminium Industry in Guinea Guinea is a country in west Africa. (This photograph was provided courtesy of Pixabay.)
By Richard McDonough* Guinea has become a major source of the raw ingredients that produce aluminium. “In 2020, it overtook China as the second-largest producer of bauxite, and production is expected to continue to rise,” according to a document from the European Parliamentary Research Service. The Republic of Guinea Ministry of Mines and Geology in its Mining Statistics Bulletin dated 1 November 2021 reported that 64,766,327 tonnes of bauxite were produced in Guinea from 1 January 2021 through 30 September 2021. The same report indicated that 312,050 tonnes of alumina was produced in the country during the same first three quarters of 2021. The Mineral Commodity Summaries 2022, a report issued by the United States Geological Survey (USGS), indicated that bauxite reserves in Guinea were estimated at 7,400,000,000 tonnes. This USGS report indicated that 86,000,000 tonnes of bauxite were produced in Guinea in 2020, with 85,000,000 tonnes of bauxite produced in the country in 2021. The European Union reported that the EU was the top trading partner with Guinea in 2020; overall, total trade – both imports and exports – between the EU and Guinea represented 22.3% of its total trade in goods. According to this EU report, China was number two in total trade with Guinea, India was number three, the United Arab Emirates (UAE) was number four, and Japan was number five. These five nations represented almost 67% of all trade between Guinea
and other countries. The long-term potentials for Guinea were highlighted in the Market Overview of Guinea published by the International Trade Administration (ITA) of the US Department of Commerce on 1 July 2019. This report indicated that “China has dramatically increased its role through investment agreements in recent years, as exemplified by its September 2017 decision to loan (US) $20 billion to Guinea over a 20-year timeline…Endowed with abundant mineral resources, Guinea has the potential to be an economic leader in the extractives industry. Guinea is home to 35% of the world’s reserves of bauxite (aluminum ore). Bauxite is the most active mining sector in Guinea, accounting for 34% of Guinea’s exports [at that time.]” The report from the ITA continued by noting that together with the companies then operating bauxite mines in Guinea, “...new market entrants are expected to significantly increase Guinea’s bauxite output over the next five to ten years.” This West African nation has seen difficulties in recent years as the country has sought to increase its production of bauxite and alumina. Non-governmental organisations active in human rights – including Inclusive Development International and Human Rights Watch – have called attention to activities that the organisations have indicated are creating problems for residents near production facilities as well as impacting the overall nation. In addition, as with other countries, Guinea has also had to
deal with the impacts of the COVID-19 Pandemic during the past two years. Tensions within Guinea increased on 5th September 2021, when a military coup took place in the country. The elected national government was removed from power. In the months since, both bauxite mining and alumina refining have continued in Guinea. A number of countries from Europe to Asia and from Africa to the Americas expressed concerns about the overthrow of the previous government in Guinea. Josep Borrell Fontelles, High Representative/Vice President in charge of coordinating the external action of the European Union, issued a statement via Twitter on the day of the coup: “I condemn the takeover by force in #Guinea and call for the immediate release of President Alpha Condé. I invite all actors to act in accordance with the rule of law, the interest of peace, and for the well-being of the Guinean population.” On the 6th September 2021, the Ministry of Foreign Affairs of the Russian Federation issued a statement indicating that “We are following with deep concern the developments in our friendly Republic
*Do you have questions about the aluminium industry? Governmental regulations? Company operations? Your questions may be used in a future news column. Contact Richard McDonough at aluminachronicles@gmail.com. © 2022 Richard McDonough Aluminium International Today
Richard Alumina.indd 1
March/April 2022
02/03/2022 10:47:03
12 THE ALUMINA CHRONICLES
A conveyor carrying bauxite is seen here at the EGA port in Kamsar, Guinea. (The photograph was provided courtesy of EGA.)
of Guinea, where on 5th September, in the capital of the country, Conakry, a group of military men led by the former commander of a special forces battalion, Colonel M. [Mamady] Dumbuya, carried out an armed seizure of power. According to incoming reports, the conspirators stormed the residence of the head of state, arrested President A. [Alpha] Condé, announced the suspension of the Constitution, the dissolution of parliament and government. A curfew has been introduced in the country; borders have been closed. At present, the location of A. Condé is unknown.” “Moscow opposes any attempt at an unconstitutional change of power,” the statement continued. “We demand the release of A. Condé ensuring his immunity. We consider it necessary to return the situation in Guinea to a constitutional track as soon as possible. We urge all Guinean political forces to refrain from actions that could provoke further violence and to work towards a peaceful and negotiated settlement of the current situation.” On 5 September 2021, Ned Price, spokesperson of the US Department of State, reported that “The United States condemns today’s events in Conakry. Violence and any extra-constitutional measures will only erode Guinea’s prospects for peace, stability, and prosperity. These actions could limit the ability of the United States and Guinea’s other international partners to support the country as it navigates a path toward national unity and a brighter future for the Guinean people. We urge all parties to forego violence and any efforts not March/April 2022
Richard Alumina.indd 2
supported by the Constitution and stand by the rule of law. We reiterate our encouragement of a process of national dialogue to address concerns sustainably and transparently to enable a peaceful and democratic way forward for Guinea to realise its full potential.” Though the views of the USA had not changed, on 2 October 2021, Antony Blinken, the US Secretary of State, issued a statement in honour of Guinea National Day: “On behalf of the United States Government and the American people, I
congratulate the people of Guinea on the 63rd anniversary of your independence. Today, we reflect on the aspirations of all Guineans for a democratic, prosperous, and peaceful future. The United States continues to stand by the Guinean people in their pursuit of these goals. In the weeks ahead, we will work together with Guineans and the international community to help Guinea reestablish constitutional rule, provide good governance, and strengthen public health to ensure a brighter future for all Guineans.” The USA informed the Government of Guinea in that same month of its decision to terminate the designation of Guinea as a beneficiary of trade preferences through the African Growth and Opportunity Act (AGOA). The termination took effect on 1 January 2022. According to the US Department of State, “President [Joseph] Biden determined that Guinea has not established, or not made continual progress toward establishing, the rule of law and political pluralism or the rule of law and is thus out of compliance with the AGOA eligibility criteria required to warrant designation as an AGOA beneficiary. The United States is encouraging Guinea to rapidly hold free and fair elections and fulfil the AGOA eligibility criteria to allow us to mutually beneficial trade and investment between Guinea and the United States.” A news statement from the Office of the United States Trade Representative (USTR) explained that the “AGOA provides eligible sub-Saharan African countries with dutyfree access to the U.S. market for over 1,800 products, in addition to the more than 5,000 products that are eligible for
An employee with GAC is seen here with a train at the end of the tracks at the EGA mine in Tinguilinta, Guinea. (The photograph was provided courtesy of EGA.)
Aluminium International Today
02/03/2022 10:47:12
14 THE ALUMINA CHRONICLES
Several GAC employees are seen at company offices at Kamsar, Guinea. (The photograph was provided courtesy of EGA.)
duty-free access under the Generalized System of Preferences programme. To meet AGOA’s rigorous eligibility requirements, countries must establish or make continual progress toward establishing a marketbased economy, the rule of law, political pluralism, and the right to due process. Additionally, countries must eliminate barriers to U.S. trade and investment, enact policies to reduce poverty, combat corruption and protect human rights.” The USTR indicated that the USA “…is deeply concerned by the unconstitutional change in [government]…” in Guinea and that that nation “…has clear benchmarks for a pathway toward reinstatement…” in the trade preference programme of the AGOA. Whilst expressing disapproval and ending trade preferences, the USA provided at least five deliveries of large volumes of COVID-19 vaccines to Guinea since the time of the military coup. According to the US State Department, on the 24th September 2021, the USA delivered 336,000 doses of the Johnson & Johnson COVID-19 vaccine to Guinea; on 7th October 2021, the USA delivered 588,510 doses of the Pfizer COVID-19 vaccine to Guinea; on 14 November 2021, the USA delivered an additional 168,000 doses of the Johnson & Johnson COVID-19 vaccine to the people of Guinea via COVAX; on 6 December 2021, the USA partnered with Gavi COVAX to deliver 299,520 COVID-19 vaccine doses to Guinea; and on 17 January 2022, the USA partnered with Gavi COVAX to deliver 299,520 COVID-19 vaccine doses to Guinea. Through all of these difficulties, though, March/April 2022
Richard Alumina.indd 3
bauxite mining and alumina refining have continued in Guinea. Businesses active in the aluminium industry with headquarters in China, France, Russia, Singapore, the UAE, the United Kingdom, and the USA, among other nations, have operations in Guinea. Emirates Global Aluminium - Guinea Alumina Corporation One of the largest aluminium businesses operating in Guinea is Emirates Global Aluminium, the owner of Guinea Alumina Corporation. “Emirates Global Aluminium (EGA) is the world’s largest ‘premium aluminium’ producer – value-added products made to customer specifications,” according to a spokesperson for EGA. “We are an integrated global aluminium giant, with a bauxite mine in the Republic of Guinea, an alumina refinery in Abu Dhabi, and aluminium smelters in Abu Dhabi and Dubai.” The firm noted that EGA was founded as “Dubai Aluminium” in 1975, with production beginning in Jebel Ali in Dubai in 1979. Jebel Ali has been expanded numerous times over the years. Emirates Aluminium in Abu Dhabi began production in 2009, with a second phase starting up in 2013. During the next year, in 2014, Dubai Aluminium and Emirates Aluminium merged to form EGA. “For most of our history we were a midstream company, focused on aluminium smelting,” explained the spokesperson for EGA. “Over the past few years, we have expanded upstream and internationally, building a bauxite mine in Guinea and an alumina refinery
in Abu Dhabi. Both these projects began production in 2019.” Mubadala (one of EGA’s 50% shareholders today) and Dubai Aluminium first acquired a stake in Guinea Alumina Corporation (GAC) in 2007, according to GAC. The two companies acquired a 100% stake in 2013. GAC indicated that the bauxite mine project got the go-ahead from the Guinean National Assembly in 2014, with first exports of bauxite from Guinea in August of 2019. “Phase 1 of the GAC project is a bauxite mine and associated export facilities,” stated the spokesperson for EGA. The overall project includes “a 690 square kilometre bauxite mining concession inland from the coast. In the area to be developed by 2040, our concession contains almost 400 million tonnes of bauxite mineral resources.” Among the infrastructure built includes a shared railway to the coast, located about 90 kilometres away. “We have our own trains,” the spokesperson for EGA continued. Infrastructure also includes “port facilities at Kamsar, with bauxite loaded onto barges for movement to a transshipment location in deeper water. This enables us to use Capesize vessels for ocean shipping. We invested some (US) $1.4 billion to develop GAC, one of the largest greenfield mining investments in Guinea in the past 40 years. We have some of the largest mining equipment in Africa.” According to the EGA spokesperson, 2,600 people – both employees and onsite contractors – work at GAC; 93% of the workforce is Guinean. The nameplate capacity is 12 million tonnes per year. Much of the bauxite mined by GAC is supplied to third-party customers, noted the spokesperson for EGA, with some portion of the bauxite produced in Guinea sent to the UAE for further processing at its alumina refinery. In 2020, the first full year of production, the EGA spokesperson stated that “…we were the second largest supplier of bauxite in the world to third party customers.” Customers include, among others, Vedanta, Bosai Minerals Group, and Xinfa. During the first six months of 2021, Guinea Alumina Corporation exported 5.85 million tonnes of bauxite ore as ramp-up continued, up from 5.47 million tonnes in the second half of 2020 and 4.26 million tonnes in the first half of 2020. Compagnie des Bauxites de Guinée Among global aluminium businesses involved in Guinea are Alcoa and Rio Tinto. According to a statement from Alcoa, the company “…is a joint owner of Compagnie des Bauxites de Guinée, Aluminium International Today
02/03/2022 10:47:17
TOGETHER TOWARDS PERFORMANCE
NOW IS THE TIME TO ACT REEL is on a journey contributing towards a net-zero Aluminium Industry.
reelinternational.com
REEL Aluminium is a major solution provider dedicated to reduce the carbon footprint in the Aluminium industry. Both internal and external par tnership, new ways of understanding and innovative technological investments in the development of net-zero solutions for the Aluminium industry are the best conditions for REEL‘s goals to work together on its path to decarbonization and to green Aluminium future.
16 THE ALUMINA CHRONICLES
Boké is a major bauxite producing area in Guinea. (The image was taken from a video provided courtesy of Human Rights Watch, 2018.)
(CBG). CBG was formed in 1963 by the Government of Guinea and Halco (Mining), Inc. (Halco) to develop bauxite in the Boké region. The Government of Guinea owns 49% and Boké Investment Company owns 51% of CBG. Halco owns 100% of Boké Investment Company. Alcoa World Alumina LLC, a majority-owned subsidiary of Alcoa, owns 45% of Halco.” Rio Tinto reported in its annual report that it also owned 45% of Halco. In addition, Dadco reported that it is a shareholder of Halco; the firm is an international group active in the aluminium industry. “With more than 2,200 employees, the Company [CBG] mines the world-class Sangarédi bauxite deposit in northwestern Guinea, recognised for its rich ore body containing approximately 50 % alumina,” the statement from Alcoa continued. “CBG exports approximately 15 million tonnes of high-grade bauxite annually. Mining rights extend until 2038.” RUSAL In Guinea, RUSAL has three major bauxite mining operations in Dian-Dian, Friguia, and Kindia. According to the firm, “Dian is the largest bauxite deposit in the world with proven reserves of 564 million tonnes. The right to develop it belongs to RUSAL.” In addition to a bauxite mine, the Friguia production complex also includes an alumina refinery. “Managed by RUSAL since 2002, and privatised in 2006, [this operation] includes a 160 kilometre railway network that facilitates shipments of products, raw materials and fuel,” according to a statement from RUSAL. The firm reported that the annual production March/April 2022
Richard Alumina.indd 4
capacity at Friguia includes 600,000 tonnes of alumina and 2.1 million tonnes of bauxite. Compagnie des Bauxites de Kindia (CBK) “…is RUSAL’s largest raw materials asset and accounts for about 25% of the company’s total bauxite output,” according to RUSAL. “CBK was established in 2001 on the basis of the production base of the national Guinean company SBK. CBK started to produce and export bauxite in May 2001. It is developing one of the largest bauxite deposits in the world.” The company reported that the annual production capacity here is 3.5 million tonnes of bauxite. On the 9th February 2022, RUSAL reported its operating results for calendar year 2021. According to the firm, RUSAL produced 7,489,000 tonnes of bauxite in 2021; in 2020, it was 7,435,000 tonnes of bauxite. RUSAL reported that it produced 414,000 tonnes of alumina at its Friguia Alumina Refinery in Guinea. In 2020, this refinery produced 439,000 tonnes of alumina. SMB Winning Consortium The SMB-Winning Consortium, according to the group, includes four entities working together: Winning Shipping Ltd. of Singapore; UMS, a French transportation and logistics company that has had a presence in Guinea for more than 20 years; and Shandong Weiqiao, a leading Chinese aluminum production company; the Republic of Guinea is a partner and shareholder of up to 10%. In a news statement dated 18th June 2021, the SMB-Winning Consortium
announced that “…a new ore export railway as part of the Boffa-Boké Project. With this new structuring project, the Consortium’s leadership will be strengthened and will contribute to developing a more sustainable and environmentally-friendly bauxite supply chain…Crossing the Boké and Boffa regions, this 125 kilometre railway is intended to link the Santou II and Houda deposits to the river port of Dapilon. The new line includes 21 bridges, two tunnels, and six depots and is the first line built in the country since the 1970s…Initially, the railway will be exclusively devoted to the transport of ore before also serving in the long term for the transport of other industrial and agricultural products.” The news statement indicated that the SMB-Winning Consortium had invested about (US) $3 billion in various components of its Boffa-Boké project and that the Consortium exported approximately 40 million tonnes of bauxite from Guinea in 2020. “The SMB-Winning Consortium wishes to embody the principles of integrity and responsibility as part of a win-win approach with all of its stakeholders to contribute to the growth of the Guinean mining industry and economic development. across the country,” said Sun Xiushun, Chairman of the SMB-Winning Consortium. “Dialogue and coordination with all Consortium stakeholders are at the heart of the deployment of the Boffa-Boké Project: local communities, Guinean NGOs, local authorities, Guinean subcontractors, public administration, international partners of the Consortium,” stated Fadi Wazni, Chairman of the Board of Directors of the SMB-Winning Consortium. “Together, we will be able to make the Boffa-Boké Project a structuring project for the development of Guinea.” Human Rights Watch Jim Wormington, Senior Researcher, Business and Human Rights at Human Rights Watch, wrote on 11th October 2021 that “Guinea’s 5 September coup sent shock waves through both West Africa and global commodities markets.” He noted that the coup raised “... fundamental questions about the future of Guinea’s mining sector and whether Guineans will benefit from the country’s mineral wealth or continue to pay the price for its exploitation...Mining companies have largely been unfazed by the coup. But for an industry that benefitted so much from the [previous]...government’s limited oversight and weak regulation, the transition creates both an increased risk of human rights abuses and an opportunity to improve, if government and industry are willing.” � Aluminium International Today
02/03/2022 10:47:19
18 MINING & REFINING
Bauxite arriving at Alcoa’s Wagerup Refinery
Australia’s Bauxite and Alumina Industries – Partnering to reduce emissions through technology While much of the global focus is on decarbonising the aluminium smelting sector, the emissions associated with the mining of bauxite and refining of alumina are not being forgotten. Australia has more than 50 years of technical experience in bauxite mining and alumina refining technologies. This experience helps not only us, but our bauxite, alumina and aluminium customers, to reach their sustainability goals. Alcoa, Rio Tinto and South32’s Worsley Alumina operations all have their global research headquarters in Australia, helping develop new technologies for the world. Australian bauxite and alumina will help meet global demand for aluminium Australia is the world’s largest producer of bauxite, mining more than 100Mt March/April 2022
mining AAC refining.indd 1
of bauxite a year, or about a quarter, of global production. About 40% of this is exported and 60% is turned into alumina here in Australia. We are the world’s second largest producer and largest exporter of alumina, with production of more than 20Mt a year. Of this, about 85% is exported and the remaining 15% is turned into aluminium at the nation’s four smelters. Meeting the continued and increasing global demand for primary aluminium will require proportionate increases in production of bauxite and alumina. Australia’s alumina already has some of the lowest emissions in the world, with an average emissions intensity of 0.7 tonnes of carbon dioxide per tonne of alumina (t CO2-e/t), compared to the global industry average of 1.2 tCO2-e/t. However, as a large producer and exporter, alumina
emissions are a disproportionately large part of the Australian aluminium industry’s footprint, accounting for just over 40% of sector’s emissions. By comparison, while Australia produces around 100Mt a year of bauxite, national emissions from bauxite production are only 1% of the total Australian aluminium industry’s emissions. Helping develop low carbon alumina mining and refining technologies for the world In 2021, the members of the Australian industry announced a number of key strategic partnerships to trial and commercialise key decarbonisation technologies within mining and refining operations. Also in 2021, the Australian Aluminium Council welcomed four new members, including South32’s Worsley Aluminium International Today
28/02/2022 15:42:42
s
Rio Tinto’s Yarwun Refinery
Marghanita Johnson, CEO of AAC
in the refineries using, and in some circumstances where the co-generation is large scale, exporting low emissions electricity. About 5-10% of an alumina refinery’s energy is used in electrically driven pumps, fans and conveyors. Alternate Technologies
Alumina operations, made up of its bauxite mine and alumina refinery. South 32’s membership means the Council now represents all five of Australia’s major bauxite mines and all six of its alumina refineries. Having the full value chain of Australia’s major producers collectively represented strengthens the industry’s domestic and global voice on key policy issues, including decarbonisation. Aluminium smelters are already electrified, so no technological conversion is required to enable them to run on renewable electricity, or a grid mixed with variable renewables, providing the electricity is supplied consistently with firm power. By contrast, alumina refineries have, to date, used thermal energy derived from gas, coal and fuel oil, supplemented by electricity. Alumina refining is an energy intensive process, using about 10.5 GJ / t alumina produced. Digestion and calcination are the two most energy-intensive steps, with digestion consuming around two thirds of this energy. All of Australia’s alumina refineries have some combined heat and power generation (cogeneration) facilities which use a combination of coal, gas, or biomass fuels. This cogeneration results
Electrification There are a number of potential pathways which would enable renewable electricity to be used as the primary source of energy in the digestion phase of alumina refining: � Mechanical Vapour Recompression (MVR) which uses electricity to drive mechanical vapour compressors to upgrade waste steam. Using renewable electricity for MVR would displace fossil fuel derived thermal energy. MVR technology is well established in other industries, but not currently used at the large scale required for an alumina refinery. � Electric boilers can be used to generate steam and are commercially available, however are only likely to be commercially competitive when combined with an existing planned capital replacement and renewable energy. Alternate Energy Sources As well as electrification, there are a
MINING & REFINING 19
number of alternate energy sources the industry is considering: � Concentrated solar thermal – this is a hybrid technology which could replace 30-45% of the energy used in the Bayer process with energy derived from concentrated solar thermal technology. � Cogeneration plants can be cofired on biomass. Despite the technical feasibility of this option, the volume of biomass required given the high heat requirements for alumina refineries is limiting. � Hydrogen - The industry is currently investigating options which include the production and use of renewable hydrogen in its processes, particularly in the calcination, as the required temperatures could be difficult to achieve with electrification. Additionally, hydrogen could potentially be used to replace gas in boiler technologies for digestion. Electricity and Demand Response Australia’s grid-connected bauxite mines and alumina refineries already provide some demand response to the grid. However increased supply of competitively priced zero emissions electricity, could allow a material increase in the electrification of alumina refineries. This, when combined with demand response, could supplement electricity firming, helping to boost the broader
Alcoa's Wagerup Refinery
Aluminium International Today
mining AAC refining.indd 2
28/02/2022 15:44:56
20 MINING & REFINING
penetration of variable renewable electricity. Electrification of Australia’s six alumina refineries would materially affect grid demand, with a large fully electrified alumina refinery having potentially the
Case Study In May 2021 Alcoa of Australia Limited (Alcoa) announced it had received funding from the Australian Renewable Energy Agency (ARENA) to test the potential use of renewable energy technology in a process known as Mechanical Vapor Recompression (MVR). Alcoa is currently conducting technical and commercial studies to adapt MVR technology to refining. Electricity sourced from renewable energy would power compressors to turn waste vapor into steam, which would then be used to provide refinery
same electricity consumption as a smelter (i.e., ~ 1000MW of electricity). Australia also has a number of bauxite mines that are not grid connected and selfgenerate electricity in remote areas, largely
process heat. If the feasibility studies are successful, Alcoa plans by the end of 2023 to install a three-megawatt MVR module with renewable energy at its Wagerup refinery in Western Australia, to test the technology at scale. The MVR technology powered by renewable energy could reduce an alumina refinery’s carbon footprint by 70%. The technology also has the potential to significantly reduce water use in the refining process by capturing water vapor that would otherwise be lost to the atmosphere.
Weipa’s First Solar Plant - Aerial View
Case Study Rio Tinto announced a partnership with ARENA in June 2021, to conduct a feasibility study investigating the potential to partially decarbonise its alumina refining operations using renewable hydrogen. Rio Tinto will investigate the technical implications of displacing natural gas with renewable hydrogen at its Yarwun alumina refinery in Gladstone, particularly focussed on simulating the use of hydrogen in the calcination process. In August 2021, Rio Tinto announced a further partnership with Sumitomo Corporation to study the construction of a hydrogen pilot plant at Rio Tinto’s Yarwun alumina refinery in Gladstone and explore the potential use of hydrogen at the refinery. Importantly, the findings of these studies may have applications in other high temperature Australian manufacturing processes, beyond alumina and even beyond the mineral processing sector. Additionally, if successful, the technical and commercial lessons could lead to the implementation of hydrogen calcination technology, not only in Australia, but also internationally.
March/April 2022
mining AAC refining.indd 3
using diesel power stations. In September 2021, Rio Tinto approved a new solar farm and battery storage at Weipa to more than triple the local electricity network’s solar generation capacity, with work expected to be complete by late 2022. The new 4MW solar plant and 4MW/4MWh of battery storage will complement the existing 1.6MW solar farm. Importantly, the battery system will help provide a stable power network for both the bauxite mines and the Weipa township. When complete, the combined facility and upgrades to the existing power generation network will reduce annual carbon dioxide emissions by about 20,000 tonnes - the equivalent of taking more than 3,750 cars off the road. While this reduction may be modest for an aluminium smelter, emissions from bauxite produced are less than 0.5% of the aluminium mine to market emissions, making this a substantial for this operation. Beyond Mining and Refining In addition to looking at bauxite and alumina specific technologies, the Australian Aluminium Council and its members are working across major industry to help accelerate the development of technologies which may have multiple applications in the transformational change required to achieve net zero emissions. In June 2021, the Australian Government announced a ten-year partnership arrangement with the Heavy Industry Low-carbon Transition Cooperative Research Centre (HILT CRC). The Council, Alcoa, South32 and Rio Tinto are all partners in the HILT CRC which focuses not only on alumina but also on iron, steel, cement, lime, hydrogen and ammonia. Australia has a unique opportunity to leverage the critical clustering of skills, resources and energy demand in the regions in which alumina refineries and aluminium smelters are located. Partnering across industries provides a framework for industry to collaborate, sharing knowledge and experience while lowering the risk of trialling technology. Conclusion Australia is leading the way in developing technologies for the adaptation of brownfield alumina refineries to lower carbon technologies. It is here where global emission alumina trials are being conducted. The need for low carbon solutions applies across the global mine to market aluminium sector. Australian industry certainly demonstrated its commitment in 2021 and will continue to do so for many years to come. � Aluminium International Today
28/02/2022 15:45:36
Aluminum processing fluids
Hot & cold rolling mills TotalEnergies is a leading global manufacturer and marketer of lubricants, with 42 production sites around the world and more than 5,800 employees in 160 countries. TotalEnergies’ Lubricants division offers innovative, high-performance and environmentally friendly products and services, developed by its R&D centers, which employ over 130 researchers. TotalEnergies’ lubricants division is a key partner for players in the automotive, industrial and marine markets.
lubricants.totalenergies.com
TotalEnergies Industry Solutions
ms.industry@totalenergies.com TotalEnergies 552 006 454 RCS Nanterre - France. Photos: 123RF - Design:
22 MINING & REFINING
A closer look at Metro Mining
A high-quality bauxite producer to watch is Metro Mining Ltd situated in the world class Western Cape York bauxite region in far northern Queensland, Australia. After launching in 2018, it has recently transformed its shiploading capability to Capesize vessels and is set to trigger a 50% expansion this year. This is its story.
In 1963 Comalco commenced commercial production at its now renowned Weipa bauxite mines. Today, the total capacity from Western Cape York exceeds 40 Million Tonnes Per Annum (Mt/a). Metro Mining Ltd is the entity that emerged from the 2014 takeover of Cape Alumina Ltd by MetroCoal Ltd. Metro is listed on the Australian Stock Exchange (ASX: MMI) with mining operations having commenced in 2018 and based on the current reserves is expected to continue until at least 2037. It has earned a reputation as a major, independent, and reliable Australian bauxite producer. The Bauxite Hills Mine has reserves of 100 Mt and resources of a further 30 Mt from leases which cover around 1,900 sq. March/April 2022
mining Metro mining .indd 1
kilometres, one of the largest holdings in Western Cape York. The mine is located at Skardon River around 90km north of the township of Weipa. As a remote but world-class mining operation, Bauxite Hills boasts state-of-the-art infrastructure including an all-weather airstrip, modern camp, a screening and barge loading facility, haul and light vehicle roads. Situated in a remote tropical savanna. environment, Bauxite Hills is a relatively low energy and impact operation with minimal permanent footprint. One key advantage is the simple mining operation. The direct shipping ore is located near the surface and does not need blasting to allow mining. Once the ore is dry screened it is loaded onto barges that are towed out
to sea for trans-shipping into ocean going vessels, predominantly bound for China. Rehabilitation is conducted on an ongoing basis as soon as possible following mining to minimize degradation of topsoil and the contained seeds. The introduction of a new $14 Million Floating Crane Barge, “TSA Skardon”, in 2021 to the Bauxite Hills operation resulted in Metro being the only bauxite supplier in Australia to service customers in the largest vessel class, cape size, with tonnages up to 180,000 metric tonnes. Metro produces a classic Western Cape York-style pisolitic bauxite, one of the highest alumina bauxites in the world. Bauxite Hills Mine’s proximity to Asia and large vessel capability has significant Aluminium International Today
03/03/2022 08:49:56
MINING & REFINING 23
is committed to ensuring Metro is a partner of choice for the local Ankamuthi people. Through the implementation of community engagement strategies and development activities we continue to look for opportunities to deliver longterm and sustainable benefits to our host communities and Metro remains committed to local employment and supplier programs.” Through 2021 Metro enjoyed an average 28% Indigenous staffing level, and through ongoing training initiatives and programs this is likely to increase to over 30% in 2022. During 2021 Metro was pleased to have paid approximately $1.55 million in total royalties to the Ankamuthi and Old Mapoon Aboriginal Corporation Trusts and was pleased to see these royalties directly benefiting local people and our local communities, and in particular, being able to realise benefits to the communities through initiatives focussed around improving access to education and on-line learning, emergency relief and culture. As Metro looks forward, it sees a bright future for Aluminium and its value chain. A critical metal for light-weighting and the energy transition, demand is assured whilst barriers to supply have risen along with economic rationality. As with other non-ferrous and base metals, a structural price re-rating should allow margins to grow in the up-stream value chain. The CM Group is forecasting a 30 Mt/a increase in the Chinese bauxite market to 2031 but with an 80 mt/a increase in imports as domestic mines reduce supply. There will also be growth outside China.
Thus, demand for high alumina bauxite, located close to the alumina refineries and produced in a low risk jurisdiction in a low impact process provides customers with a compelling value and risk equation. This positive environment is enhanced by Metro’s market positioning to work with customers on meeting their needs through a high quality and consistent supply, low cost delivered freight solutions, technical service and a creative win-win approach to contracting. Metro expects that discussions will lead to further medium and longer term contracts which will underpin approval of an expansion from four to six million tonne per annum capacity later in 2022. As well as expansion, Metro is actively working on improving value and sustainability through product quality upgrades, equipment productivity and renewable energy alternatives. �
advantages including lower costs, reduced travel and turnaround times. After commissioning, in 2018 Metro shipped over two million tonnes of bauxite to six customers in China. Since then, sales have increased to over three million tonnes per annum with the target for 2022 of four million tonnes. Native Title and Land Access Agreements are in place and indigenous workers make-up a significant proportion of the mine’s workforce and proudly, the mine enjoys strong community support. Metro CEO, Simon Wensley says: “Mutual respect and building trust with our local communities remains paramount to Metro Mining’s ongoing success. The Metro leadership team Aluminium International Today
mining Metro mining .indd 2
March/April 2022
03/03/2022 08:50:26
MINING & REFINING 25
High Purity Alumina – Another way aluminium is part of the clean energy revolution By Marghanita Johnson* had a high carbon emission intensity. However, as new processes are being designed there are opportunities to reframe this expectation and develop low carbon HPA products. This reflects a broader emerging trend in supply chain management, where companies and their customers increasingly expect that products and the raw materials that comprise them, are produced with a minimal carbon footprint. The applications for HPA in low carbon markets are growing, making HPA a critical mineral of the future.
Aluminium oxide (Al2O3), better known as alumina, has been produced in Australia for more than fifty years and is largely supplied to the global aluminium smelting industry as metallurgical grade alumina, usually at purities of more than 99%. Australia is the world’s second largest producer and world’s largest exporter of metallurgical grade alumina, producing more than 21 Mt per annum. Alumina refineries can also produce alumina for a range of non-metallurgical uses, including water treatment; production of aluminium fluoride; ceramics, refractories and abrasives. HPA – How many Ns However, there has been an emergence in demand for very high purity alumina’s. Known as just that – High Purity Alumina (HPA) – the products range in purity of more than 99.99% (4N) through to purities of more than 99.9999% (6N). While the difference between 99% (known as 2N) and 4N may be subtle, it has a profound impact on everyday items in our lives. HPA was first developed in the 1940’s with the primary application being directed to the war effort as a substitute route for making aluminium metal. The production cost was higher than standard aluminium production, so post war HPA production was largely neglected. Until about five years ago, HPA had a very small market demand of only 15,00016,000 tonnes per annum. More recently demand has grown due to the need for its quality, purity and versatility in high-tech applications. Today the market stands at more than 30,000 tonnes per annum and has been widely forecast to have a compound annual growth rate (CAGR) of about 20%. This increased demand is driven by an increased global demand for a new world of technologies. HPA’s properties such as high brightness, resistance to
Marghanita Johnson
corrosion, good thermal conductivity, high melting point, chemical stability and high mechanical strength make it suitable for manufacturing various electronic and vehicle components, including for both electric vehicles and the aeronautical sector. It is used to make safer, more efficient and longer lasting lithium-ion batteries, synthetic sapphire for LED lighting and high technology optics. Use of HPA in battery technologies which would mean batteries have about a 30% higher retention capacity compared to conventional anode materials, with potential cost benefits and increased range for electric vehicles. There are many other niche applications for HPA in a ceramic form which include abrasives, substrates and electrical components. Like many manufacturing processes, production of HPA is energy intensive with the higher order refining needed to increase purity generally requiring higher energy use. HPA has traditionally used aluminium as a feedstock, and then chemically converts it back to alumina. This has meant that historically, HPA has
Australia is developing novel processing technologies Given the positive CAGR and Australia’s long track record in the alumina industry, it is not surprising that there are now a range of novel Australian HPA projects in the pipeline. In 2021, the Australian Aluminium Council took the strategic decision to represent the HPA industry as well as traditional metallurgical alumina producers. This recognises the role of this new HPA product in meeting the clean energy challenge as well as the recognition of the number of projects which are interwoven with the existing industry. Indeed, it is the strong regional bauxite and alumina industry in Australia which is being leveraged to create these new manufacturing opportunities. The HPA projects have also received strong support from both the Australian and state governments, recognising the important role of HPA as a critical mineral. For example, the Council’s first HPA member, Alpha HPA, has announced its intention to construct what would potentially be the world’s largest high purity alumina plant in Gladstone, with targeted production of 10,000 tonnes per annum. Gladstone is well known as the location of Rio Tinto’s Yarwun and Queensland Alumina Ltd refineries, as
* Chief Executive Officer, Australian Aluminium Council Aluminium International Today
mining alumina.indd 1
March/April 2022
28/02/2022 15:51:07
26 MINING & REFINING
well as the Boyne aluminium smelter. The Alpha HPA process will use a precursor sourced from one of the alumina refineries in its “Smart SX” (solvent extraction) refining technology. The Alpha process also works with other neighbouring manufacturers so that by-products from its extraction process can be recycled, making the project an almost zero discharge facility. The solvent extraction technology, combined with renewable energy, aims to generate a range of HPA products with a carbon footprint lowered by as much as 60%. Alpha and Rio Tinto are both signatories to the Queensland Government’s Statement of Co-operation for industries co-operating toward net zero emissions manufacturing. Another well-known alumina refining location is south Western Australia. In 2021, integrated bauxite miner, alumina refiner and aluminium producer, Alcoa of Australia announced an HPA joint development project with FYI Resources Ltd. The project will have three main stages of development before potential construction, in 2024, of a full-scale 8,000 tonnes per annum HPA plant. This project is a natural complement to Alcoa’s existing business, building on the company’s expertise in alumina refining technology development and production capability. While Rio Tinto’s Bell Bay Aluminium in northern Tasmania is still an operating aluminium smelter, between 1956 and 1972 the site also operated as an alumina refinery. As a result, it has a Tailings Storage Facility (TFS) housing red mud, commonly known as bauxite residue, a by-product of the Bayer process. Peloton Resources has proposed to construct an HPA pilot plant to valorise this bauxite residue to extract HPA and other critical minerals. Up to 15 tonnes per year of residue is proposed to be processed with the pilot plant to
Alpha HPA Laboratory
be sited immediately adjacent to the tailings storage facility, within the Bell Bay Advanced Manufacturing Zone. There are also a range of other projects, where HPA may be produced alongside other critical minerals. Developing new projects and novel processes today, means the Australian HPA industry is setting itself up for success as a location for low carbon and low waste production facilities of the future.
development of these new opportunities, which can be made in Australia and distributed to the world as part of the ever-growing range of products we will need to meet technology challenges – today and into the future. �
Conclusion HPA is one of the many exciting new aluminium products, including aluminium alloys and salts, emerging to meet the needs of the global energy revolution, at the same time as satisfying increased consumer demand for the highest ESG standards of production. Australia is strategically positioned to support the
FYI Resources 99.999% (5N) HPA
Alpha HPA Pucks
mining alumina.indd 2
28/02/2022 15:51:54
When you need to know it’s safe* ARL iSpark. The trusted standard. Metal is the backbone of our society. It’s in the structures we ride, work and live on every day. That’s why you’ve trusted the detection technology inside every ARL iSpark for over 80 years to ensure every piece of steel and metal you produce is safe. With so much riding on that, why would you choose anything else?
Find out more at thermofisher.com/ispark *Based on a data comparison, completed by Thermo Fisher Scientific in 2021, of detection limits for OES systems using data published in specifications and applications notes for ARL iSpark and competitors. ©2021 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified. AD41409 0821
28 MINING & REFINING
Renewable hydrogen could reduce emissions in alumina refining On behalf of the Australian Government, the Australian Renewable Energy Agency (ARENA) recently announced up to $579,786 in funding to Rio Tinto to support a feasibility study investigating the potential to partially decarbonise its alumina refining operations using renewable hydrogen. Conventional alumina refining combusts natural gas to achieve the high temperatures necessary in the calcination process. Rio Tinto will investigate the technical implications of displacing natural gas with renewable hydrogen at its Yarwun alumina refinery in Gladstone, Queensland. The study would inform the viability of a potential demonstration project to validate the findings. The $1.2 million study, funded equally by ARENA and Rio Tinto, will comprise two distinct work packages: � Simulating the calcination process using a lab scale reactor at Rio Tinto’s Bundoora Technical Development Centre in Melbourne, Victoria. � Preliminary engineering and design study conducted at Rio Tinto Yarwun to understand the construction and operational requirements of a potential demonstration project at the refinery. The study will see an improved understanding of the potential for renewable hydrogen to be used in the alumina refining process and the scope of development works required to implement hydrogen fuelled calcination technology at an existing alumina refinery. Australia is the world’s largest producer of bauxite and the largest exporter of March/April 2022
mining RIO TINTO refining.indd 1
alumina, accounting for 15 per cent of global alumina refining capacity. Alumina refining is an energy intensive process that uses high pressure steam to produce the heat required to process bauxite into alumina. Alumina can then be converted to aluminium in a smelting process. ARENA has identified the alumina sector as a key target in its strategy to support industry to reduce emissions due to the potential size of emissions abatement. In 2019, alumina refining accounted for over 14 million tonnes of carbon dioxide in Australia, which represents approximately 24 per cent of Australia’s scope 1 manufacturing emissions. The Australian Government’s first Low Emissions Technology Statement highlights the importance of developing a low emissions steel and aluminium industry to help reduce emissions and stimulate economic activity. Innovation in metals refining can improve the competitiveness and emissions intensity of Australia’s steel and aluminium production. Last month, ARENA announced $11.3 million in funding for Alcoa to investigate and deploy an alternative technology that uses recycled steam for process heat powered by renewable energy. ARENA CEO Darren Miller said Rio Tinto’s study would explore the potential for hydrogen to reduce emissions across the aluminium supply chain and would complement ARENA’s support for Alcoa’s project. “If we can replace fossil fuels with clean hydrogen in the refining process for alumina, this will reduce emissions in the energy and emissions intensive
refining stage of the aluminium supply chain. Exploring these new clean energy technologies and methods is a crucial step towards producing green aluminium. This study will investigate a potential technology that can contribute to the decarbonisation of the Australian alumina industry. If successful, the technical and commercial lessons from Rio Tinto’s study could lead to the implementation of hydrogen calcination technology, not only in Australia, but also internationally,” he said. Rio Tinto accounts for approximately a third of Australia’s total alumina production capacity. Rio Tinto is aiming to reach net zero emissions across its operations by 2050. Across the company, it is targeting a 15 per cent reduction in absolute emissions and a 30 per cent reduction in its emissions intensity by 2030, from a 2018 baseline. Rio Tinto Aluminium Pacific Operations acting managing director Daniel van der Westhuizen said “We see the ARENA and Rio Tinto-funded study as a step towards reducing refinery emissions and one that has the potential to play an important part in Rio Tinto’s commitment to decarbonisation. “We’re investing in work that needs to be done, not only to decarbonise one of our sites, but also to help provide a loweremissions pathway for Rio Tinto and the global aluminium industry. “We recognise we are on a long road towards reducing emissions across our operations and there is clearly more work to be done. But projects such as this are an important part of helping us get there.” � Aluminium International Today
28/02/2022 15:59:11
MINING & REFINING 29
Solving the descaling dilemma: Robotic Arms By Malcom Caron-Boivin* Advances in robotic arms are allowing heavy industry and manufacturing to move beyond their past of adapted tooling and dangerous human tasks. The capabilities of today’s custom-made equipment allow for specialisation that more efficiently and effectively handles the risky individual jobs once – and in some cases still – performed by human workers. The rewards for companies taking advantage of these advanced capabilities include overall safer operations for employees and improved performance through operational efficiencies. Occupational health and safety and efficient productivity are fundamental to success in commodity industries like alumina and aluminium, where slim margins are easily impacted by process inefficiencies. Downtime and maintenance costs place substantial stress on cost-perton sold, but significant progress can be made by eliminating inherent dangers maximising the operational efficiency of common tasks, such as descaling. In fact, proving how important tackling a routine task like descaling can be, two major alumina producers, Alcoa and Rio Tinto, sought to improve the descaling process and reduce the impact of scale on their operations by conducting an online crowdsourcing competitions. So, how can the latest robotic arm technology minimise this traditional part of the Bayer process that slows down operations and puts human workers in hazardous situations? This article highlights the many advantages of descaling a tank (such as a desilication tank, bauxite digester or red mud thickener) with a remotely controlled descaling robotic arm rather than by more traditional methods, like installing scaffolding and having workers manually remove the scale with jackhammers or a remote-controlled vehicle.
The Descaling Dilemma A common aspect of alumina production is that capacity decreases as residue and scale build inside production vessels. Whether it’s on a digester’s shell or a thickener’s wall, significant scale builds up during multiple refining tasks, impacting tanks, vessels and pipes. Furthermore, descaling operations often delay or limit operations because of the required downtime to perform the maintenance of removing this residue, resulting in reduction of available tank volume and lost production.
Ultimately, this descaling procedure translates to downtime and both direct and indirect costs. Downtime required to perform descaling operations on a large tank can stretch between four to six weeks and require up to five workers. In addition, descaling time is often extended due to unforeseen scale conditions. Such delays disrupt and extend the entire descaling process, frequently causing even more scale accumulations within other operating vessels. Descaling is a dangerous and dirty process for humans who spend time inside
*Eng. Product Manager, EPIQ MECFOR Aluminium International Today
mining EQUIP refing.indd 1
March/April 2022
28/02/2022 15:56:02
30 MINING & REFINING
conditions while being user-friendly and reliable. When determining which solution is right for your facility, several factors must be considered. Ease of entry and use Openings and access doors to some tanks can be small and restrictive. Obviously, the descaling mechanism must first be able to get inside this opening. Once inside, the unit must be able to reach and clean the entire surface area. Complicating this task is that many tanks also have internal elements like rakes. A descaling robotic arm must be able to maneuver around these objects without damaging them. There are also considerations beyond the actual descaling process inside the tanks. The equipment must be able to travel across production floors and walkways before and after use. Some components may even need to use existing elevators to be transported to and from the use site. Therefore, your equipment should ideally be customised for the facility and its operational needs. the tanks and vessels to clean them. A typical descaling procedure might involve the installation of scaffolding inside a tank, where workers then remove the residue with jackhammers or high-pressure water jets. Depending on configuration of the reservoir, a descaling operation might also take place in confined spaces with poor ventilation. In most all cases, the workers are subjected to intensive physical labor in difficult conditions that pose major safety hazards. In some instances, scaffolding are maintained by cables on pulley to move from top to bottom of the tank. Thankfully, innovation has arrived to address the descaling dilemma. Technology offers a safer and more costeffective option: Descaling robotic arm. The Advantages of Robotic Descaling Arm SAFETY Industrial hygienists are always seeking ways to improve employee safety and reduce human exposure to dangerous working conditions – and descaling robotic arms do exactly that. With a descaling robotic arm, no human needs to enter a toxic tank. Human crews are not subjected to confined spaces that can be problematic to escape quickly should the need arise. By reducing or eliminating dangerous situations, the overall health and safety of workers is improved, and subsequently so is the company’s recordable accident rate. EFFICIENCY We’ve already noted the significant impact downtime can have on alumina March/April 2022
mining EQUIP refing.indd 2
operations and the related benefits shortening that downtime can have on overall productivity (and thereby profit). Reducing the turnaround time on descaling boosts production capacity and output. Descaling robotic arms also remove the risk of human error, which can be expensive and time consuming in multiple and variable ways, whether it’s injuryrelated or simply performing a task incorrectly or ineffectively. COST EFFECTIVE Though the biggest cost benefits may come from efficiency, there are aspects of descaling robotic arm that reduce expenses in other ways: Safety training is targeted to the equipment operators that remotely operate the descaling robotic arm and required safety gear may be less stringent. Needs Of A Robotic Arm Solution A descaling robotic arm solution isn’t the right solution if it doesn’t accomplish all the advantages described above. The equipment you chose must reduce your downtime and improve your working
Operational options Descaling is accomplished by different means. Water jetting is an option, along with flails or a hydraulic hammer. Each method has its merits and limitations, and the right method will have a lot to do with the tank design itself as well as the scale properties and the plant specific conditions. The ability to choose which method works for your specific facility is paramount to reducing damages and related costs, as well as accomplishing the most effective process results. A descaling robotic arm solution that fits into the tank but uses an ineffective or damaging method to remove the scale potentially creates more problems than it solves. Being able to select and adapt your descaling robotic arm mechanisms to the task will ensure you get all the convenience and results offers. Operation and automation Ideally, your descaling robotic arm solution is equipped with sensors and a camera system that allows a human operator to manage and control the entire process from an ergonomic, dedicated workstation. Hard automation is an option that can be looked into. This will help facilitate any human-controlled elements of the descaling, as well as understand any issues that may arise, all while keeping tabs on the procedure without ever needing to physically enter the tank. Key Takeaways Descaling is a fundamental process at all alumina refineries. Thankfully, descaling Aluminium International Today
28/02/2022 15:56:13
MINING & REFINING 31
EPIQ MECFOR is a brand of EPIQ Machinery - a company capable of supplying and improving your material handling and process flow through the carbon plant, pot room, and cast house.
robotic arm technology is offering companies safer and more cost-effective options to the traditional methods of handling this natural scale buildup. A descaling robotic arm solution must be reliable and user-friendly. It must significantly reduce the downtime of your facility while improving working conditions. A common expectation should be that it reduces your downtime by 50% and that the process can be carried out by one or a pair of workers. Finally, your unit must be sturdy and built to last long term through the harsh conditions in which it will operate. Over the past 25 years, EPIQ Mecfor has designed, manufactured, and commissioned a variety of descaling robotic arms for various tank design. It’s this field expertise that helps customers realise the potential of dramatically improved working conditions and reduced downtime, keeping facilities online and producing revenue. Our goal is to make equipment that increases safety and efficiency for our clients. We are convinced that custom descaling robotic arm can achieve these things for your facility. EPIQ MECFOR’s team has a passion for challenges. �
We are a company capable of supplying and improving your material handling and process flow through the carbon plant, pot room, and cast house.
Discover our brands
Automation and robotisation systems Heavy-duty material handling, processing and packaging systems
Mobile equipment solutions, descaling arms & anode slot cutting machines (ASCM)
epiqmachinery.com
Carbon plant and rod shop equipment
Heavy-duty automated guided vehicle (AGV)
Passion for challenges
+ 1 514 687-7678 Aluminium International Today
mining EQUIP refing.indd 3
March/April 2022
28/02/2022 15:56:32
ENGINEERING & KNOW-HOW ARE THE BASIS OF OUR BUSINESS
www.properzi.com
Our commitment focuses daily o investments made in research and development. To maintain our leadership and always present ourselves on the market with cutting-edge products, we do not spare ourselves but use all our internal skills to make every day ... the difference!
SUSTAINABLE ALUMINIUM 33
Decarbonising Hydro’s aluminium products The decarbonisation challenge represent opportunities for the aluminium industry and incentivises us to invest in innovative solutions to reduce our carbon footprint further. By Hans Erik Vatne* Sustainability and reducing carbon footprints are key success criteria for any metal producer. These aspects are gaining increased focus and becoming more and more decisive for competitiveness among materials and businesses. As some other materials have an easier way to decarbonisation, it is important for the aluminium industry that we step up our efforts in order to defend aluminium’s position as well as the industry’s huge investments in the upstream aluminium value chain. Decarbonisation throughout the value chain Hydro has a clear technology ambition to enable volumes of near-zero aluminium by 2030. By near-zero we mean aluminium products with less than 0.5 kg CO2 per kg aluminium throughout the whole value chain. This will be achieved through R&D and piloting up to industrially relevant size pilots. We pursue two main paths for near-zero aluminium; (i) Path 1: The primary path - smelter and Bayer process abatement and (ii) Path 2: The recycling path. Path 1: Decarbonising primary aluminium: Hydro is in a process to convert to natural gas and installing electric boilers at our Alunorte refinery. This will significantly reduce the carbon footprints from Alunorte, the world’s largest alumina refinery. We are also developing roadmaps for piloting hydrogen for calcination, an action that is also proposed by several industry peers. Globally, the power production is the biggest source for CO2 emissions in the smelter area. Thus, energy efficiency and conversion to renewable energy are the most important actions. On the energy efficiency side we are proud of the results of our latest electrolysis technology, the HAL4e technology. This technology has
Fig 1. Illustration of the classic Hall-Heroult smelter technology (left) and our new HalZero chloride technology (right).
been proven in the Karmøy Technology Pilot producing consistently at industrial scale with an energy consumption of 11.7 and 12.4 kWh/kg Al, for low energy and high productivity versions, respectively, and with a total CO2 emission of 1.4 kg CO2 per kg Al for the smelting process. Hydro has a good power source portfolio with a high fraction of hydropower and wind sources. We continuously work on converting the rest of the portfolio to renewable power as well. To eliminate the hard to abate emissions from the electrolysis, we are following two routes: � The first route is carbon capture and storage. It is important for us to secure the value of existing smelters, as these are some of the lowest cost assets in the industry and we have leading technology and production capabilities. For these assets we are developing CCS solutions. Here, the challenges are low concentrations of CO2 and pollution in the off-gas, which makes standard amine technology costly. We have evaluated more than 50 CCS technologies and developed a roadmap for testing and piloting the most promising up to industrial scale. The most likely outcome will be a combination of off-gas capture and direct air capture to
eliminate 100% of the emissions. � The second route, more suited for greenfield smelters, is our proprietary HalZero technology. This is a technology based on converting alumina to aluminium chloride prior to electrolysis. Carbon monoxide is used in the chlorination, in a reaction where alumina is mixed with chlorine and carbon monoxide to produce aluminium chloride and CO2. The aluminium chloride is split by electrolysis into aluminium and chlorine and the chlorine is fed back to the start of the process and kept in a closed loop. The resulting CO2 is pure and fully concentrated and is converted to carbon monoxide and oxygen, where also the carbon monoxide is fed back to the start of the process and kept in a closed loop. Thus, this becomes a process where chlorine and carbon are kept in closed loops, resulting in a fully decarbonised process, see Fig 1 for illustration. We have been working on lab-scale for three years on this technology and have developed a roadmap for piloting this to industrial scale before 2030. Collaboration with relevant stakeholders on developing public/private partnerships and securing access to carbon transport
*SVP, Chief Technology Officer, Hydro Aluminium International Today
Sustainable alu Hans Hydro.indd 1
March/April 2022
28/02/2022 16:04:04
34 SUSTAINABLE ALUMINIUM
and storage infrastructure are required to fund and industrialise these technologies at scale. Path 2: Post-consumer scrap There is also a circular path to near-zero aluminium, which is the fastest way to market. Hydro has the most advanced recycling technology and metallurgy competence in the industry. This enables us to produce Hydro Circal – a low carbon product with a certified recycled content of more than 75% post-consumer scrap. We could produce this with 100% postconsumer scrap even today, buying clean and sorted scrap, but doing this in a profitable way requires digging deeper into the scrap pile of difficult, unsorted and contaminated scrap. This means utilising and further developing our advanced sorting technology. Current state-of-the-art sorting is done by X-ray technology, but we already have an industrial pilot based on laser technology, so-called LaserInduced Breakdown Spectroscopy, LIBS, which is much more precise than X-rays and able to distinguish different alloys. 100% scrap in combination with fuel switch to renewable fuel – hydrogen,
Fig 2. Examples of existing low-carbon products.
biogas or direct electricity – for scrap melting, would take our products to zero. We see these technologies, along with our network of recyclers and their proximity to scrap suppliers and customers as a key competitive advantage to enable and capture value from more circular business models. Our ambition is to deliver first volumes of recycled products with a carbon footprint below 0.5 kg already in 2022. Downstream is very much about increased use of low-carbon aluminium and substituting less sustainable materials and high-carbon aluminium. Examples of such products are Hydro’s Reduxa and Circal, see Fig. 2. Hydro Reduxa is based on renewable power for the smelter process and thus contains less than 4 kg
of CO2 per kg aluminium, while Circal contains minimum 75% post-consumer scrap. Going forward we will gradually be able to reduce the carbon footprints of these types of products below 0.5. Hydro has a clear technology strategy for developing near-zero aluminium products before 2030. By delivering on the ambitious technology strategy, Hydro is in a unique position to become the leading supplier of near-zero aluminium. This is the most important and urgent action to build competitiveness of the fantastic material that aluminium is, but we also recognise other needs like protecting biodiversity and improving the lives and livelihoods wherever we operate, thus enabling the overall sustainability ambitions. �
Safety Storage Efficiency Manage your aluminum more safely and more productively using less space with Combilift’s materials handling solutions
• • • • •
Safer product handling Optimised production space Improved storage capacity Increased productivity & output Enhanced profits
combilift.com Aluminum Times Liz A5.indd 1
March/April 2022
Sustainable alu Hans Hydro.indd 2
09/02/2022 15:26:47
Aluminium International Today
28/02/2022 16:04:21
SUSTAINABLE ALUMINIUM 35
Hydro in the USA: A journey towards sustainability Following the big commitments made at COP26, Hydro representatives Charlie Straface* and Paul Warton** discuss the initiatives which aim to achieve greater sustainability. By Zahra Awan*** Discussing the developments of America, for me, is like discussing the developments of world far, far away. Having never visited the Continent, hearing of the ‘trip’ across the 2.615 million km2 West Coast from the office in the UK, a country whose land in total amasses 242,495 km², it’s fair to say I have yet to experience the vastness of the world. Charlie Straface detailed his travels with Paul Warton and explained that they visited facilities in The Dalles and Portland. They then went to Los Angeles to the City of Industry extrusion plant. Then to Utah and ended up in Phoenix. Hydro is one of the dominant extruders in the US with 22 manufacturing facilities in North America, with 21% of the market share. Straface went on cryptically, sharing that they “also visited one of [their] biggest customers, a very large electric vehicle company who cannot be named, but they’re headquarters are on the West Coast; most people know who they are!” I will leave the reader to decipher this riddle. The pair also visited Phoenix where ‘a state of the art 12-inch press’ is based.
As ‘another big investment is a part of the Hydro greener products strategy’, the goal of the press is to meet the demands of ‘the electric vehicle market’. Paul Warton commented: “It was great to finally be able to travel to the US and visit our plants on the West Coast. It was energising to meet face-to-face and see how the Extrusion North America team is working hard to deliver on their strategy of lifting profitability and driving sustainability. They have performed well over the years, and we have invested to further strengthen and grow our market position. One of the highlights of the tour was to see the new 60 MN 12-inch stateof-the art extrusion press at our plant in Phoenix, Arizona.” The Dalles Cast House Facility, where a $27 million investment was made for a modern recycle cast house as a part of Hydro’s greener sourcing and product strategy, was a key focus of the trip. The two main goals of the cast house investment, listed by Straface, was “one, to make the most energy efficient cast house possible and two, increase our ability to
* President of Hydro Extrusions North America ** Vice President at Norsk Hydro Aluminium International Today
Sustainable Hydro interview.indd 1
use post-consumer and/or pre -consumer scrap and use the minimal amount of primary aluminium as possible.” Hydro has “nine recycle cast houses, we are the largest remelter in North America. We cast more extrusion billet than any other company in the US. And it’s a large part of our business to be able to cast our own starting stock.” The Dalles investment, according to Straface, was key due to several reasons. Two vital reasons being: 1. Geographical location: “The facility is in the very northwest of America where there is a lack of accessibility of billet. Alcoa used to have a facility, which was shut down several years ago, meaning that accessibility of billet decreased and therefore, reduced the supply of billet to extrusion sites, lowering production. An investment was needed to secure billet in the northwest for our own extrusion, without being dependent on imports and to meet demand,” says Straface.
*** Editorial Assistant of Aluminium International Today March/April 2022
03/03/2022 09:31:32
36 SUSTAINABLE ALUMINIUM
door would be opened. Staging the scrap in front of the furnace and using charge machines to feed the furnace, we were able to save energy and increase efficiency. The door open time was cut by around 50%, the gas usage was reduced, and the melt time was cut by 30-40%.” Straface explained.
Charlie Straface
“An investment was needed to secure billet in the northwest for our own extrusion, without being dependent on imports and to meet demand.” 2. Hydro’s Recycled Content strategy: “While we were upgrading the facility, there was a focus on implementing recycling facilities to fall in line with hydro’s recycling strategy to increase the use of post-consumer scrap. Postconsumer scrap is an extrusion that has been previously used, it is material that has been used in a building or in a vehicle that has been taken, shredded, and sorted. This material can then be remelted, recycled, and reused. As it often comes dirty – mixed with plastic or other components from its previous life, stricter filtration, safety management and environmental controls are needed. To filter the metal from the additional materials, high efficiency burners, bag houses and sophisticated bunker systems are required to segregate the scrap. So, the second reason for the investment at the Dalles Facility, was to increase Hydro’s recycled and greener products strategy, by increasing our ability to use scrap, specifically zero carbon post-consumer scrap.” Warton added that the “lessons learned from this project will be transferred to Hydro’s other remelt facilities in the future.” Hydro have claimed that the new casting equipment will ‘reduce energy/ton by approximately 40%.’ Between the two Hydro representatives, the pair went onto explain the four key methods adopted by Hydro at The Dalles Facility to increase the efficiency of production and make their products greener. 1. Reusing heated air: Furnaces at Hydro are fuelled by natural gas, as the technology on renewable energy is still under experimentation. Straface continued that the “most March/April 2022
Sustainable Hydro interview.indd 2
important thing is to have state of the art efficient burners and regenerative systems to reuse the hot air that we expel back in to re melt to reuse the heat,” to make the most of the fuel used in the process of production. 2. Time and efficiency: “The shorter time it takes for us to melt and complete a job, the less energy we use. Currently we lose a lot of energy due to the time it takes for people to do certain tasks. One method of increasing the efficiency is automation. Feeding post-consumer scrap material into the furnace manually posed a serious issue with regards to efficiency. Each time a furnace would be fed material, the door of the furnace would be opened and the heat would escape, reducing efficiency. The goal was to reduce the number of times and length of time the furnace
3. The furnace capacity: “The size of the furnace was increased so that with each melt there was more output. So, the gas usage per pound of billet went down significantly,” says Straface. 4. A switch from induction systems: “The primary driver in the decreased energy consumption is a switch from induction systems to state-of-the-art natural gas-fired systems in the melting and holding furnaces,” commented Warton. Hydro claimed that their emissions control systems will allow the use of postconsumer aluminium scrap in Hydro’s billet casting process, further reducing the carbon footprint of the billet. Straface commented where control systems have been implemented: “The use of postconsumer scrap, which has zero carbon content, is the source of material we want to use more of. All recycled scrap is good, but post-consumer scrap is better. However, as post-consumer scrap is ‘more dirty’ as previously mentioned. Sorting and shredding reduces that dirtiness but doesn’t completely clean it. This is where technology is needed. With the dirty fumes of the mixed scrap, we have a very efficient fumes collection systems rather than letting the fumes enter the clean atmospheric air. “Next, we have a bag house where
“Lessons learned from this project will be transferred to Hydro’s other remelt facilities in the
”
future.
Paul Warton
Aluminium International Today
03/03/2022 09:31:58
Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, investments, and the latest products and projects Published quarterly in a digital format, Furnaces International and the new monthly newsletter, are sent to the inbox of over 25,000 industry professionals. As publishers of Aluminium International Today, Steel Times International and Glass International, we are able to compile this knowledge and bring you the latest developments on: • Energy Efficiency • Hot Repairs
• Maintenance • Heat Treatment
• Thermal Processes • Testing and Measurement
Look out for the December issue which contains The Furnaces International Buyers’ Guide. It is the essential guide to furnace manufacturers and suppliers of furnace equipment and services to the industrial heating/ process industry.
SIGN UP TODAY TO RECEIVE YOUR FREE COPY
CONTACT US NOW: Esme Horn
Sales Manager +44 (0) 1737 855136 esmehorn@quartzltd.com
Nadine Bloxsome
Editor, Furnaces International +44 (0) 1737 855115 nadinebloxsome@quartzltd.com
Zahra Awan
Editorial Assistant +44 (0) 1737 855038 zahraawan@quartzltd.com
WWW.FURNACES-INTERNATIONAL.COM
Furnaces_1p_Ad_Sept21.indd 1
27/10/2021 11:47
38 SUSTAINABLE ALUMINIUM
Sat Adusumilli, Charlie Straface, Paul Warton, Hossein Binesh
chemical processes and filtrations take out the particulates and toxins from the dirty air, which cleans the air ready to be released. This air is often cleaner than the air released when processing clean scrap.” Straface continued. Warton added that “In addition to a new baghouse system, we are installing a state-of-the-art melting furnace and holding furnace, as well as upgrading our homogenisation furnaces with ultralow NOx burners. These investments will increase the site’s production capacity, but more importantly, they will allow us to use a higher percentage of post-consumer scrap in the casting process. As a result, we will be able to significantly lower the carbon footprint of our products produced in The Dalles.” The importance and place Industry 4.0 has in Hydro was defined by Straface, who went onto explain that by “using all the information that the modern-day systems give you, and taking the data to improve the efficiency of a process is the ultimate way of utilising the benefits of Industry 4.0 technology.” Straface continued, “for example, a burner. Rather than checking it every 6 months, allowing efficiency to decrease across that period, with Industry 4.0, we can use technology to analysis everyday data to make relevant changes as an when needed. To constantly keep a piece of equipment at its optimal efficiency. This is a concept that can be ‘embraced’ across the board.” Summarised by Warton, “Advanced Industry 4.0 technology helps us achieve improved quality, reliability, and productivity and achieve benchmark energy consumption levels.” He continued, March/April 2022
Sustainable Hydro interview.indd 3
“with regards to sustainability, the ability to accurately measure and report data is critical. Industry 4.0 technologies have enabled greater detail and accuracy in data collection for the manufacturing environment, which in turn helps us to make better decisions that affect sustainability, maintenance, quality, and much more.” Onto the final subject of discussion, the topic of the role that Environmental, Social and Government Sustainability (ESG) has played during the process of developing the initiative was contemplated. Warton explained: “Hydro’s sustainability initiatives are built around three pillars: Climate, Environment and Social. We believe that the three are mutually dependent and to succeed in decarbonising the society, we must strengthen in all three areas. Hydro’s social ambition is to improve the lives and livelihoods wherever we operate. The target of empowering 500,000 people with education and skills development by 2030 was recently supplemented with business-specific targets to support just transition, and ensure responsible business practices throughout Hydro’s supply chain, providing traceability and transparency of key sustainability data for Hydro’s products.” He continued, “being a responsible business partner means that we continuously engage, influence and work with our suppliers and business associates. It is fundamental for us to understand and mitigate risks of non-compliance with our corporate responsibility requirements in the supply chain. The requirements cover issues related to environment, human rights, anti-corruption and working conditions, and are built upon the UN Global Compact, the UN Guiding Principles on Business and Human Rights and other international standards. We work to strengthen local suppliers through
supplier development programs.” Straface gave an example of a personal endeavour, which aimed at tackling the issues of diversity under his watch over the North American Sector of Hydro. Responsible for ‘22 plants which is 22 communities’, Straface emphasised the importance of community within the workplace: “One personal issue which I delt with, during the year of 2021, was diversity. With the issues of diversity being highlighted in 2021, following the murder of George Floyd, we came face-to-face with an issue that has been in the United States since the beginning. I personally got more involved in the Diversity, Inclusion and Belonging (DIB) program. Sponsored by my fellow colleagues, we started a mentorship programme to include all genders and all races to improve the diversity issue. With our 6000 employees, we are a very diverse and representative group, especially on the shop floor. However, from statistics we saw that the leadership roles on the shop floors did not match this diversity. And, I don’t believe we can have an inclusive culture if the leadership roles of employees do not match the diversity of the overall population. There are no easy fixes for this issue. But, we decided if we could identify any high potential candidates within our plants who wanted to move up to a leadership role, we would personally spend more time with them and help them understand what it takes to be a leader, and encourage them to take the leadership roles. There are around 10 -15 people in each regional workshop, of which there are regions groups across north America. 25% of these workers could be promoted to leadership roles within the year enhancing the diversity.” The discussions between the representatives of Hydro and myself brought the community of the company into view. I felt the family of the North American sector and its desire to improve the global quality of life by focusing on local changes. Charlie Straface asked to end with a thank you to Hydro’s Chief Executive Officer: “Hilde Merete Aasheim is very passionate about sustainability; I have to give her a lot of credit for inspiring us, the people in North America, and pushing us towards a greener future. I appreciate her leadership and drive towards being a leader in this CO2 reduction and sustainability mantra. She has made us believe that change is possible, and with the help of every employee under Hydro, we are making it possible.” �
Deigo Daluisio, Paul Warton, Marcos Jimenez
Aluminium International Today
03/03/2022 09:32:16
The new EVY Compact Vacuum Cleaner
FRESH THINKING, SMART CLEANING The cleanest
The leanest
The meanest
• Filters even the finest dust:
• Compact, highly manoeuvrable model
• Fully continuity-adjusted
• Reduces your Total Cost of Ownership
• Collects all dust, ready to re-use &
• Single out of stock model
re-market
2 - 0,2 micron • Cleans without dust clouds • Sustainable: better for men & machine
• It’s all about Serving Progress!
For more information about EVY: www.hencon.com/evy
www.hencon.com
40 SUSTAINABLE ALUMINIUM
Tom Giddings
Why education is key to building consumer confidence in recycling Tom Giddings* discusses the findings of a recent survey carried out by the Industry Council for Packaging and the Environment (INCPEN) and explains why better education is pivotal to building public confidence in recycling. INCPEN recently published the results of a highly insightful consumer research survey investigating the key drivers of public confidence in recycling. The results highlighted that having a reliable kerbside collection service and seeing other households recycling effectively resulted in high public confidence, while a lack of information regarding what happens to recyclable material after its collection resulted in low public confidence. On-the-whole, consumers felt more confident about kerbside collections actually being recycled compared to onstreet collections. In addition, residents in Wales, Scotland and Northern Ireland were more confident about their recyclables being reprocessed to create new products than their English counterparts. However, with the UK’s recycling rate
stagnating and increasing focus being placed on initiatives to kick-start positive consumer behaviour, will addressing consumer perceptions help to increase national recycling rates? In short, the answer is yes. But it’s important to understand the reasons behind this. Aluminium packaging recycling hits record-breaking results When it comes to aluminium packaging recycling rates, the UK continues to perform admirably. Between January and September 2021, more than 121,277 tonnes were collected for recycling. This is yet another year-on-year increase in volumes (9%) and very pleasing news indeed for the sector. While many suggested that high collection volumes experienced in 2020
were a direct result of COVID-19 lockdowns and more people working from home (rather than consuming products on-thego), data highlights that positive recycling behaviours have continued despite the easing of restrictions. But why is this? In my opinion, when it comes to aluminium, it is easier to follow the journey of spent packaging after it’s separated for recycling. Indeed, the process is simple, clear and well documented – from recycling collections to being back on the supermarket shelf in just a few weeks. What’s more, rather than being shipped across the globe, thanks to its intrinsically high value and widespread use as an infinitely circular packaging material, a high percentage is responsibly reprocessed within the UK and Europe (86% of all material collected). Even the
*General Manager, Alupro March/April 2022
Sustainable aluPro.indd 1
Aluminium International Today
28/02/2022 16:09:05
SUSTAINABLE ALUMINIUM 41
fraction of aluminium packaging that escapes recycling collections and ends up in energy from waste (EfW) facilities can be recovered to create new products. The data is well publicised, the information is accurate and the supply chain is transparent, which results in better engagement and more effective recycling rates – the circle is self-perpetuating. Education is key to kick-starting recycling rates The challenge, for the entire supply chain, is to improve education about the recycling process. Rather than expecting householders to understand the intricacies of post-kerbside collections, we need to drive the conversation and provide the required information. After all, the biggest challenge seems to be building public confidence in the fact that recyclable material, once collected, actually is recycled. When it comes to aluminium packaging, this is absolutely the case. Indeed, data suggests that 75% of all aluminium ever manufactured is still in the value chain. As such, Alupro continues to invest heavily in educating the public. Through our consumer engagement programmes –
Every Can Counts and MetalMatters – we connect with millions of consumers every year to explain the benefits of recycling and reassure them about the process; from collection to reprocessing. We welcome new partners to help us communicate the message of aluminium recycling to even more householders nationwide. So, while consumers should have high confidence about recycling, the industry has a real job to do when it comes to
building trust, addressing misconceptions and educating consumers. If we can build this confidence, we can achieve better engagement rates and higher recycling rates. This said, it’s a task for the entire supply chain to tackle – collaboration is key! � For more information about Alupro, visit www.alupro.org.uk.
RefractoryTechOL1/4 pg.qxp_Layout 1 2/17/22 3:06 PM Page 1
Consultancy and technical support to the aluminium industry • Build long-term partnerships with our aluminium experts • Solve your current aluminium production problems • Prepare a downstream business case • Detailed investigation and testing • Product and process training courses • Aluminium industry expertise
Tel: +44 (0) 1295 702800
Email: enquiries@innovaltec.com
www.innovaltec.com Aluminium International Today
Sustainable aluPro.indd 2
March/April 2022
28/02/2022 16:09:28
LIGHTENING THE IMPACT OF HEAVY INDUSTRY
SPEAKERS CONFIRMED INCLUDE:
Lord Adair Turner Chair Energy Transitions Commission
Let’s turn talk into action. Hosting top government officials, heads of industry, leading scientists, exciting innovators and the largest international investors, Sustainable Industrial Manufacturing (SIM) in Belgium will provide an opportunity for leadership teams in hard-toabate sectors to find the experts and technology needed for a transition towards net zero.
Andrew Purvis
Pernelle Nunez
Derek Baraldi
Gökçe Mete PhD
Head of Sustainable Finance Investing, Banking & Capital Markets Industry, World Economic Forum
Head of Secretariat, Leadership Group for Industry Transitions (LeadIT) and Research Fellow Stockholm Environment Institute
Cédric de Meeûs
Dolf Gielen
Vice-President, Group Public Affairs & Government Relations Holcim
EARLY BIRD TICKETS NOW AVAILABLE FOR JUST £485 Includes access to the high level conference, exhibition, roundtable debates, delegate lunch and a plethora of networking opportunities and side events.
SCAN ME FOR THE WEBSITE
Executive Director Mission Possible Partnership
Director Safety Deputy Secretary General Environment and / Director – Sustainability Technology International Aluminium World Steel Association Institute
JOIN THE LEADERS, BE PART OF THE SOLUTION
Organised by:
Anthony Hobley
Director IRENA Innovation and Technology Centre
Christina Sobfeldt Jahn
Head of PPA Origination & Execution Ørsted
Henning Bloech
Ilhan Savut
Director of Sustainability Extruded Solutions Norsk Hydro
Chris Bayliss
Anne-Claire Howard
Global Director Sustainable Solutions Mitsubishi Chemical Advanced Materials
Director of Standards Aluminium Stewardship Initiative
Pinakin Chaubal
Dilip Chandrasekaran
Vice President & Group CTO ArcelorMittal
Dr Jörg Rothermel
Managing Director Energy, Climate Protection, Raw Materials German Chemical Industry Association (VCI)t
Jean-Marc Moulin
Lead Analyst - Circular Economy BloombergNEF
Head of R&D and Technology Kanthal
Philippe Bastien Regional President, Architectural Glass Division AGC Glass Europe
CEO ResponsibleSteel
Stefan Grüll
CEO and Co-Founder S1Seven GmbH
Zakia Khattabi
Minister of the Climate, The Environment, Sustainable Development and Green Deal, Belgium
Sponsored by:
Part of:
REGISTER TODAY www.SustainableIndustrialManufacturing.com
SIM DPS.indd All Pages
17/01/2022 09:42
LIGHTENING THE IMPACT OF HEAVY INDUSTRY
SPEAKERS CONFIRMED INCLUDE:
Lord Adair Turner Chair Energy Transitions Commission
Let’s turn talk into action. Hosting top government officials, heads of industry, leading scientists, exciting innovators and the largest international investors, Sustainable Industrial Manufacturing (SIM) in Belgium will provide an opportunity for leadership teams in hard-toabate sectors to find the experts and technology needed for a transition towards net zero.
Andrew Purvis
Pernelle Nunez
Derek Baraldi
Gökçe Mete PhD
Head of Sustainable Finance Investing, Banking & Capital Markets Industry, World Economic Forum
Head of Secretariat, Leadership Group for Industry Transitions (LeadIT) and Research Fellow Stockholm Environment Institute
Cédric de Meeûs
Dolf Gielen
Vice-President, Group Public Affairs & Government Relations Holcim
EARLY BIRD TICKETS NOW AVAILABLE FOR JUST £485 Includes access to the high level conference, exhibition, roundtable debates, delegate lunch and a plethora of networking opportunities and side events.
SCAN ME FOR THE WEBSITE
Executive Director Mission Possible Partnership
Director Safety Deputy Secretary General Environment and / Director – Sustainability Technology International Aluminium World Steel Association Institute
JOIN THE LEADERS, BE PART OF THE SOLUTION
Organised by:
Anthony Hobley
Director IRENA Innovation and Technology Centre
Christina Sobfeldt Jahn
Head of PPA Origination & Execution Ørsted
Henning Bloech
Ilhan Savut
Director of Sustainability Extruded Solutions Norsk Hydro
Chris Bayliss
Anne-Claire Howard
Global Director Sustainable Solutions Mitsubishi Chemical Advanced Materials
Director of Standards Aluminium Stewardship Initiative
Pinakin Chaubal
Dilip Chandrasekaran
Vice President & Group CTO ArcelorMittal
Dr Jörg Rothermel
Managing Director Energy, Climate Protection, Raw Materials German Chemical Industry Association (VCI)t
Jean-Marc Moulin
Lead Analyst - Circular Economy BloombergNEF
Head of R&D and Technology Kanthal
Philippe Bastien Regional President, Architectural Glass Division AGC Glass Europe
CEO ResponsibleSteel
Stefan Grüll
CEO and Co-Founder S1Seven GmbH
Zakia Khattabi
Minister of the Climate, The Environment, Sustainable Development and Green Deal, Belgium
Sponsored by:
Part of:
REGISTER TODAY www.SustainableIndustrialManufacturing.com
SIM DPS.indd All Pages
17/01/2022 09:42
44 ALUMINIUM SHOW PREVIEW
“A true world-leading trade fair”
ALUMINIUM 2022 will start in Düsseldorf on September 27. And it will, after the cancellation in 2020, finally be the long-awaited and international industry meeting of the aluminium industry and its application industries. The central players in the industry will be there, as will the most exciting start-ups and newcomers. The trade fair will also score points with new special shows, cooperation with the most relevant associations and industry partners, with numerous hybrid elements - and with three days full of content. When can a trade show call itself the “world’s leading trade show”? What makes it the most important meeting place for an industry? If it’s a matter of the pure exhibition space that represents a world market within the framework of a trade fair, ALUMINIUM (September 27-29, 2022) more than lives up to the term, because as in previous years, it represents the global aluminium market within six exhibition halls at the Düsseldorf Exhibition Center. And another criterion is also met: The most important players in the industry will be there to guarantee professional exchanges of the highest relevance. Among others, Norsk Hydro, HAI Hammerer, AMAG, ALVANCE, Rio Tinto, Alcoa, Trimet, Rusal or Assan Alüminyum have already confirmed their participation. In addition to many other well-known industry giants, numerous SMEs and startups will also provide enormous diversity. The most important issues of our time But of course there is more to it than that. A world-leading trade fair is expected to offer answers to the most pressing questions of the present and the future. The content of ALUMINIUM 2022 will March/April 2022
Aluminium Show.indd 1
therefore focus on those topics that are already transforming the industry. And for which the material offers numerous approaches to solutions.
of the megatopics of the near future. Aluminium as a material for facades or window frames will play a central role in this.
- Sustainability: Few materials offer as many opportunities for recycling and circular economy as aluminium. At the trade show, numerous innovations will be presented in the sense of climate-neutral aluminium. - New mobility: The pressure to make vehicles lighter and the increasing importance of electromobility are making aluminium an increasingly important material in the automotive industry. - Additive and digital manufacturing: 3D printing is becoming increasingly established in industry. However, the topic is far from being exhausted. In Düsseldorf, corporations as well as start-ups will demonstrate exciting new ways of combining the material properties of the metal with the design freedom of additive manufacturing. - Digitalization: More efficiency, more effectiveness innovative engineering and machine software will be another focus of the show. - Building and Construction: Smart and environmentally friendly cities are one
Special shows with strong partners Two of these focus topics will be reflected in their own special shows. “Additive and Digital Manufacturing” in Hall 5 will highlight the diverse technical possibilities offered by 3D printing. For trade fair project manager Malte Seifert, this is one of the most exciting developments in the industry: “3D printing makes it possible to combine the material properties of aluminum with the design freedom of additive manufacturing. What new approaches this offers cannot even be fully foreseen today.” The exclusive partner for this special show is the Aachen Center for Additive Manufacturing (ACAM) at RWTH Aachen University, one of the world’s most important research centers in this field. In Hall 6 of ALUMINIUM, everything will revolve around the topics of sustainability and recycling. Against the backdrop of the excellent properties of the material in the sense of a circular economy, numerous best practices and innovations await trade show visitors in the “Innovation Plaza Sustainability and Recycling”. Aluminium International Today
28/02/2022 15:23:19
ALUMINIUM SHOW PREVIEW 45
Content drives the trade show Both special shows will be accompanied by Speakers’ Corners. They offer a dense program of expert presentations, focused content and insights on the most important issues in connection with additive manufacturing and sustainability. They will provide in-depth information and give space to the presentation of products and solutions. The thematic stages will be hosted by top-class industry partners who will contribute both thematically and professionally. The focus on content is one of the
outstanding features of the world’s leading trade show. One of the highlights: Aluminium Deutschland’s major ALUMINIUM Conference will be an integral part of the fair from 2022. It will be held under the title “Aluminium - the solution provider” in Hall 3 of Messe Düsseldorf and will focus on the central themes of the fair. The ALUMINIUM Conference will continue the approach of the extremely successful ALUMINIUM Business Summit and will bring experts, key players and, above all, customers from
the aluminium industry onto the stage to discuss the focal topics. Marius Baader, Managing Director of Aluminium Deutschland, sees the merger of the trade fair and conference as a logical step: “ALUMINIUM is now even better positioned in terms of organisation and content, and covers the cutting-edge topics that are driving our industry today and will do so in the coming years. On this stage, we can communicate the solution competence of the material and the industry more strongly and clearly.” A superlative showcase Like all of organiser RX’s trade shows, ALUMINIUM will feature hybrid elements and provide a digital trade show portal. In addition to digital exhibitor profiles, there will also be the option to follow the ALUMINIUM Conference live on the web. There will also be hybrid offerings such as audio guided tours, digital trade show bags, lead scanning of all visitors and more. “We will experience a superlative performance show in September,” promises Malte Seifert, “it will be a trade fair that the industry can be proud of - a true world-leading trade fair in fact.” �
WELCOME TO THE WORLD OF PRODUCTIVITY
Pressta Eisele is the number one supplier of high speed and precision saws for the aluminum industry worldwide. We manufacture from simple single station saws to fully automatic cutting lines with loading magazines and handling stations anything a modern production needs to keep up with the steadily increasing market demands.
Aluminium International Today
Aluminium Show.indd 2
www.pressta-eisele.de
March/April 2022
28/02/2022 15:24:10
9/11 JUNE 2022 BOLOGNA ITALY EXPO OF CUSTOMIZED TECHNOLOGY FOR THE ALUMINIUM, FOUNDRY CASTINGS & INNOVATIVE METALS INDUSTRY 12th edition. In conjunction with MECSPE
ALUMINIUM FOR THE GREEN TRANSITION
TECHNOLOGICAL INNOVATION ECO-SUSTAINABILITY CIRCULAR ECONOMY COMPETITIVENESS IN THE MANUFACTURING SECTOR ENERGY SAVING INDUSTRIAL TRANSITION Project and management
in collaboration with
Follow us on
WWW.METEF.COM
METEF
2022 47
METEF 2022 The “infinite” applications of aluminium: The global turnover of the whole sector in Italy exceeds 40 Billion Euros. To cope with the new challenges, METEF returns to BolognaFiere from 9 to 11 June, at the same time as MECSPE. Sustainability, circular economy and technological innovation are at the forefront of the new edition of METEF, the international expo for the aluminium, foundry and innovative metals industry From automotive to electronics, from transport to mechanical processing, up to the construction industry, over the last decades aluminium is more and more used in everyday life and in the industrial field. Aluminium. A sector with “infinite” end use applications, which in 2021, just for the first productions and transformations in Italy is worth a turnover of 12 billion euros (+30% on 2020), employing more than 15 thousand people1, and that for the whole chain, including final uses, counts a turnover of more than 40 billion euros2. A sector that will play a strategic role in the pursuit of international industrial decarbonisation goals. Aluminium, in fact, besides being cheap, light and flexible, can be recycled and reused indefinitely in production processes, with extraordinary positive effects in terms of circular economy and energy saving. This is done definitely in order to take advantage of the new challenges and opportunities in the sector that METEF, the international expo for the aluminium, foundry and die-casting, transformation, processing, finishing and end-use industries, will be returning to BolognaFiere from 9 to 11 June 2022. The event, now organised by Senaf, will be
held at the same time as MECSPE, the most important event dedicated to innovations for the manufacturing industry. “METEF returns to focus on its role as a national and international driving force to assist SME in the aluminium sector, which make up about 95% of the workforce and over 70% of the turnover of the industry in the European Union - says Mario Conserva, President of METEF - From Bologna, the new edition of METEF will be projected onto the international scenario and will have to bring together all the players in the supply chain, both national
and international, to set up the priorities of this sector. And it will do so by being able to count on the concomitance with the main exhibition for the manufacturing industry, MECSPE, which for years has been a reference point for entrepreneurs who want to innovate production processes.” For 25 years, METEF has been highlighting the main developments in the international light metal industry through a busy program of conferences, events, special initiatives and demonstration activities.
1 Source CentroAl 2 Source A&L Magazine - Aluminium and Alloys Aluminium International Today
Metef.indd 1
March/April 2022
28/02/2022 15:34:51
48 METEF 2022
Like the Aluminium Extrusion Forum, METEF will focus on the use of aluminium extrusions in various sectors, from construction to mechanics and transport. The Light Alloys Castings Foundry Conference (Convegno Fonderia Getti in Leghe Leggere) will deal with the current framework and prospects of the aluminium castings foundry through the analysis of the drivers of the industrial, university and institutional scenario. Looking at the end uses, the automotive sector is of primary importance for aluminium and its alloys, the topic will be the focus of the Aluminium and Cars Conference (Convegno Alluminio e Auto) during which the latest news on materials, technologies and applications will be presented against the issues relating to lightening, the availability of raw materials and the relevant regulations. Aluminium is considered the “metal of the future” in terms of technological flexibility, circular economy and ecosustainability, all aspects that will be the focus of the Green Aluminium Conference, an event that will take place in Bologna with its second stage, in which the main qualities of eco-sustainable aluminium, both primary and secondary production,
will be presented. Finally, to highlight the work of the key players in the sector, the METEF Innovation Award will return in 2022, an international initiative, consolidated for over a decade, which aims to to reward the most innovative case histories submitted by enterprises, related to innovation in plants, technologies, products and applications in aluminium and its alloys. The prize, which will be awarded to the winners on the first day of the fair, will be divided into six different categories - materials, machines and plants, technologies and processes, products, components and systems, applications, miscellaneous - and will be awarded by a jury of specialists, who will evaluate the candidatures on the basis of the degree of originality and competitive advantages that the proposed innovations are able to offer, giving priority to aspects of energy saving, eco-sustainability and resource protection. A special prize will also be awarded to projects aimed at decarbonizing the company system as a whole. “Metef was the first exhibition in the world that grasped the extraordinary development capabilities of aluminium - says Riccardo Ferrario, president of
AMAFOND - it is no coincidence that it was born in Italy, which has always been a world leader in materials, technologies and uses of light metal and its alloys. It is for this reason that as AMAFOND, the Italian association of manufacturers of machinery, plants, equipment and products for the foundry industry, we have always participated and supported Metef in all phases of growth and development, starting from the first edition of the fair in 1997. Even more so, we have given our support to the forthcoming Metef 2022 in Bologna, together with Mecspe. Light metal has in fact acquired exceptional importance worldwide among materials for all kinds of applications, both because of its eco-sustainability and because of its strong spread in important segments of industry and economy such as automotive, construction and packaging. The Italian manufacturing industry, the second largest in Europe after Germany, is very connected to and dependent on aluminium, which is why we support a major international trade fair on the sector like Metef.” � For more information on the event, visit: https://www.metef.com/it/
The Greener Aluminium Online Summit will bring together aluminium professionals and representatives to discuss how the industry must adapt towards creating a more greener approach to aluminium production. The one-day conference and virtual exhibition held on the 24th May 2022 will allow attendees the opportunity to have live discussions, network with new contacts, arrange video meetings and exchange resources and information.
FOR MORE INFORMATION VISIT ALUMINIUMTODAY.COM/GREENER-ALUMINIUM March/April 2022 Untitled-2 1
Metef.indd 2
Aluminium International Today 24/02/2022 13:04
28/02/2022 15:35:01
Pushing the boundaries for low-carbon aluminium Aluminium production comes with a footprint. Hydro works to push the boundaries for low-carbon production. Hydro REDUXA® is our series of low-carbon aluminium. Through modern technology and the use of renewable energy from hydro, wind and solar, we can produce cleaner aluminium than ever before. Visit hydro.com/reduxa to learn more.