FOIL
ENERGY EFFICIENCY
STRIP PROCESSING
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CHINESE LANGUAGE SUPPLEMENT
There is only one Optifine™ the world’s best Grain Refiner
Innovative casthouse solutions t +44 (0) 121 684 0175
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62 CONTENTS: CHINESE SUPPLEMENT
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Chinese supplement May/June 2020
CONNECT WITH CHINA As business and supply chains in China start the road to recovery, and demand from downstream manufacturers increases following the Coronavirus shutdown, we are supporting the aluminium manufacturing industry with this dedicated Chinese Supplement. The idea behind this special publication is to provide a vital resource as aluminium manufacturers look to understand how new technologies can play a part in reducing costs, increasing efficiencies and optimising their manufacturing during this challenging time. With an extended distribution to aluminium smelters and producers in China and the wider region, the articles are available in both English and Chinese language, offering a unique and timely opportunity for international suppliers and OEMs to showcase products and services to this important market.
CASTHOUSE TECHNOLOGY
COVER FOIL
ENERGY EFFICIENCY
STRIP PROCESSING
随着中国商业和供应链开始 复苏之路，并且在新冠病毒疫 情后下游制造商的需求增加， 我们将通过这一专门的中文 增刊来支持铝制造业。 该特别出版物的初衷是提供 重要资源，因为铝制造商希望 了解新技术如何在这一艰难 时期内降低成本，提高效率并 优化制造过程。 这些文章以中英文两种语言 提供给中国和更广泛地区的 铝冶炼厂和生产商，从而为国 际供应商和OEM提供了独特 而及时的机会，向这个重要市 场展示产品和服务。
Aluminium lady is back - MQP to showcase ground-breaking refiner
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CHINESE LANGUAGE SUPPLEMENT
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铝伴侣归来 - MQP 将展示 里程碑性的细化剂
ENERGY EFFICIENCY 65
Less dross and higher energy efficiency
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更少的浮渣和更高的能效
READY FOR INDUSTRY 4.0
There is only one Optifine™ the world’s best Grain Refiner
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Innovative casthouse solutions t +44 (0) 121 684 0175
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| www.mqpltd.com
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New generation of Novelis PAE “hands free” casting
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Cover picture courtesy of MQP
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Novelis PAE 新一代的“免手动”铸造
FOIL
Nadine Bloxsome, Editor, Aluminium International Today
与中国的联系
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Future concepts in battery foil production
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蓄电池箔材生产中的未来概念
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STRIP PROCESSING 71
REDEX Group opens technical centre for strip processing solutions
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瑞德克斯集团开设了一个新的技术中心，进一 步增强集团提供金属带材处理方案的能力
SMELTING SOLUTIONS 72
OxyTM offers new lease of life for long-suffereing carbon anodes
SEARCH FOR ALUMINIUM INTERNATIONAL TODAY
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OxyCIR™ 让长期遭受侵蚀的碳电极重获新生
NADINE BLOXSOME， ALUMINIUM INTERNATIONAL TODAY 编辑
May/June 2020
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Aluminium International Today
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CASTHOUSE TECHNOLOGY 63
China stand
Visitors to last year’s Aluminium China show might well remember the ‘Aluminium Lady’, an iconic symbol representing aluminium specialist MQP’s unwavering pledge to raise industry standards and the quality of what is potentially one of the world’s most sustainable materials. This year, she’s back at stand 11K71, with MQP set to unveil its latest, ground-breaking work in the ongoing development of its pioneering grain refiner, Optifine…
Aluminium lady is back - MQP to showcase ground-breaking refiner Game-changer With the climate change agenda hotting up, aluminium has come to the fore as one of the most environmentally efficient materials, resulting in casthouses having to rapidly increase production of high internal and surface quality slabs and billets to produce everything from aluminium car roof panels, cosmetic trim and aeroplane fins and skins to lightweight cladding. While the market has grown exponentially, however, the process of grain refinement has left a lot to be desired, resulting in casthouses still relying on variable quality grain refiners and ultimately, having problems in reaching the required internal and surface quality Aluminium International Today
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standards demanded by customers. With this widescale problem in mind, MQP developed what pledges to be one of the most efficient grain refiners on the market, Optifine. First used in production in regular production in 2010, this ground-breaking innovation can achieve the level of grain refinement needed to avoid ingot cracking at up to 80% lower addition rates than standard TiBAl grain refiners, resulting in improved quality and reducing operating costs by typically 50% over a wide range of aluminium alloy compositions. Produced in a state-of-the-art facility by MQP’s new partner, STNM, Optifine is now achieving exceptional results in the
production of over three million tonnes of aluminium alloys annually in 34 major casthouses worldwide, and is increasing its market share in around the world and particularly China and Asia. “The development of Optifine came about due to our own experience of the aluminium industry and observing the day to day problems that casthouses experience in dealing with a range of grain refinement related issues which occur from time to time such as cracking, large grain sizes and high incidence of both internal inclusions and surface defects, often resulting in scrapped or downgraded product and ultimately waste,” said MQP chairman John Courtenay. May/June 2020
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64 CASTHOUSE TECHNOLOGY
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Hexagonal plates
LiMCA chart
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Optifine workshop
“Companies were demanding better quality products and through the launch of MQP, we came up with a unique high efficiency grain refiner, Optifine. Today, we operate through a network of regional sales managers, consultants and distributors in all parts of the aluminium world, from Australasia to South Africa, Europe to the Americas. In recognition of the huge potential in the growing Chinese market we formed MQP China in 2018 to spearhead our market entry. The results Demonstrating just how innovative and effective Optifine is, if casthouse completely converts to using Optifine, the cost would look like this: Typically a large smelter or remelt casting 300,000 tpy would purchase 300t of standard grain refiner at a cost of $1,170,000. When converting to Optifine we guarantee to reduce costs by half saving $585,000! On top of this, a 70% reduction in the amount of grain refiner used means the number of potential particles that can cause casting defects is reduced by 70%. Evidence for this can be seen in a recent study using LiMCA at a major casthouse that regularly uses Optifine. There are also benefits for casthouse personnel, who have to make less coils changes per week, with less transportation around the casthouse and less inventory in the warehouse.
Filter life <100T <800T <1700T <2400T <3100T >3100T
Opticast Optifine is routinely used in casthouses in conjunction with MQP’s Opticast system, a unique technology and methodology for the in-line control and optimisation of grain refinement. Conceived by Lennart Backerud and Rein Vainik at Stockholm University, it has been successfully adopted into routine production in aluminium plants worldwide to improve quality and reduce costs. “With Optifine high efficiency master alloy, and the grain refinement process closely monitored with our Opticast system, the risk of cracking of ingots and billets is virtually eliminated,” said John. “Providing comprehensive technical support to casthouses is a key part of what we do, ensuring optimum Optifine addition rates can be reached safely and consistently to deliver maximum savings.” Importantly the Opticast Technology is also at the core of MQP’s extensive testing and quality control regime under the leadership of Dr Rein Vainik at our laboratory facilities near Stockholm, Sweden. Our guiding philosophy is that testing should be carried out completely independently of the manufacturing operation to ensure the gold standard of Optifine’s high efficiency is maintained at all times. Future growth In terms of growth, the new partnership with STNM has literally been a gamechanger. In 2016, after five years of trials, sales of Optifine really took off, seeing 67% growth on 2015, with tonnage increasing to nearly 1,000t, equal to 3,000t of standard grain refiner or 10% of the market outside of China. With such growth, MQP concluded that a new production facility was needed and an agreement was signed with STNM, Hebei Sitong New Metal Material Co. With a 70% shareholding in MQP, STNM now produces Optifine at its plant in Baoding, which is capable of producing
16,000 tpy of grain refiner, increasing to 38,000 when the new plant extension is commissioned later this year. John said the partnership with STNM meant MQP was geared up to bring new grades of Optifine grain refiners to market in the near future. “STNM is an excellent partner and we are benefitting from Optifine being produced in a modern, high capacity production plant, with planned expansions, significant expenditure on R&D, new product introductions, extensive global stocking facilities and excellent quality control,” he said. Ground-breaking research MQP is currently undertaking a major, twoyear research project at Brunel University to find ways to improve the efficiency of Optifine even further. The research is being conducted using High Resolution Transmission Electron Microscopy (HRTEM). There are only four such units in existence worldwide and MQP has unique access for the purpose of the unprecedented study. “Theories point towards the possibility that effective grain refinement can only take place once a layer of Al3Ti has been deposited on the surface of TiB2 particles,” said John. “Using this state-of-the-art electron microscopy, the surface of TiB2 particles can be studied at the atomic level revealing the true nature of Al3Ti layers. “We can distinguish the number of atomic layers involved and, therefore, the thickness of the layer. The equipment can also distinguish the composition of those atoms, which can possibly help in the understanding of the poisoning mechanism with respect to transition elements, such as Zr. By studying this, we hope a solution to the poisoning problem can be found. “As leaders in advancing melt quality, we are committed to innovating to benefit the industry as a whole,” he added. �
For more information, visit www.mqpltd.com. You can also follow MQP’s developments on LinkedIn and Twitter. May/June 2020
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ENERGY EFFICIENCY 65
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Less dross and higher energy efficiency By Benjamin Köster*
Over 65 installations of the QUADRAFLO SWEEP© Aluminium Melting System have shown various benefits compared to conventional air fuel and oxy fuel systems, (Fig 1): • Proven Energy Saving 15-60% • Typical heat dross reduction about 20% and more • Reduced cycle time and increased melting capacity • Low NOx and reduced CO2 emissions • High bath coverage with less burner installed • Extended furnace refractory life time • Improved control
The QUADRAFLO SWEEP© Aluminium Melting System is an oxygen based combustion system. Of course oxygen burners are generally more energy efficient than cold air or pre-heated air burner, but how is it possible to reduce the dross so drastically, when applying oxygen combustion technology? Aluminium is the third most abundant material in Earth´s crust. Aluminium metal has a strong affinity for oxygen and because of this affinity aluminium does not occur as a metal naturally in nature. Therefore you may ask how and why is it possible to use pure oxygen with natural gas to melt aluminium without increased oxidation. It is achieved through proper application of oxygen burner technology within an aluminium melting or holding furnace. XOTHERMIC Inc. has developed the QUADRAFLO Sweep© Aluminium Melting System. Instead of applying a burner used in other high temperature applications like glass, steel, copper or other related fields, XOTHERMIC researched aluminium melt applications and developed through field trials an optimal design. The QUADRAFLO SWEEP© Aluminium Melting Technology offers the highest energy efficiency, lowest dross formation for the best economics.
Fig 1. Two QUADRAFLO SWEEP© burner flame pattern
Hotwork International has the license for the QUADRAFLO SWEEP© Technology, being a direct partner for the industry to apply this technology in cooperation with XOTHERMIC Inc. Design philosophy Our initial penetration into the aluminium market was secondary aluminium Reverbratory furnaces. This is the traditional furnace utilised worldwide for both primary and secondary aluminium melting. It is primarily a refractory lined steel box with energy input from a combustion system, an exhaust port, cold metal charge port, in some cases a separate dross port and a molten metal discharge port. There are many configurations of this design, however the basic principle of operation is the same for all designs. A heat source from the combustion system transfers heat into the cold metal with sufficient force to cause the metal to retain the heat until the melting point is reached, on average 657°C. During this process it is most desirable to do this heat transfer with minimum amounts of oxidation. Further heating is required to provide sufficient energy to maintain the aluminium in a molten state during the final end process of the production cycle,
on average 750°C. What causes excess oxidation? All aluminium forms an oxide layer from interaction with the oxygen in the atmosphere. This degree of oxidation depends on the age of the metal and its condition, such as paint, enamel or other types of passivation. This in most cases, is minor. The oxidation that is referred to is oxidation created during melting as a byproduct of the combustion process. Excess oxidation is generally generated from exposure of the cold charge to excessive heat and oxygen concentrations. How to prevent excessive oxidation? This is the main premise behind the design philosophy of the QUADRAFLO SWEEP© Aluminium System. We designed a burner system that minimised generation of a hot spot on the charge material. This was achieved with the use of a flat fishtail shaped flame that moved or swept across the charge. Another requirement is that burner velocities are low momentum to minimise disturbing the molten metal bath. The flame movement is up to a 45-degree angle. Moving the flame over a period of several seconds allows the heat to be transferred over a significantly greater area than a fixed flame. Fixed flame burners heat an area of the charge
CEO, HOTWORK International AG www.hotwork.ag Aluminium International Today
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66 ENERGY EFFICIENCY
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to excessive temperatures in an effort to transfer heat to other parts of the pile. This creates significant hot spots and greater dross formation. Also provided are flow control systems that maintain a very close tolerance on the oxygen to fuel ratio. This is vital as you are paying for the oxygen and therefore do not want to waste it, excess oxygen, even with air creates more dross. It must be understood that regardless of the oxygen source, air or pure oxygen, the excess oxygen is still the same, on the order of several percent. Because pure oxygen is used, does not mean the dross will go up. It is the excess temperature that has a greater effect. In fact putting a blanket of pure oxygen over a bath of molten aluminium at 657 degrees C and no flame will show little or no increase in dross over a blanket of air at 21 percent oxygen.
Fig 2. Burner block and typical set-up
Application and experience As mentioned before, there are numerous reverb and other furnace designs therefore there is a demand for Individual design modifications unique to the particular furnace design and application.
Fig 3. Reverb furnace with QADRAFLO SWEEP© burner 49 mton tilting reverb Burner position
Tilting reverb Regenerative to Oxygen Conversion Oxygen burners produce about 60-80% less exhaust gasses than an air burner as the nitrogen has been removed. This results in better energy efficiency, less NOX
Air fire
Oxygen burner competitors
Quadraflo sweep Roof
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Fig 4. Table comparison
Fig 5. Reverb furnace with QUADRAFLO SWEEP© burner
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Fig 6. Tower Melter with QUADRAFLO SWEEP© burner
production and less gas to clean prior to exhausting to the atmosphere. The energy efficiency compared to regenerative burner can be as high as 50% better. On top, the furnace pressure can be reduced significantly, avoiding flames during high fire to damage refractory and furnace doors, etc. The Furnace generally operates cooler as with air fuel burner. Various conversation have proven: • Energy saving 35-40% • Dross reduction: 20-40% • Melt rate increase: 20-40% Oxygen to Oxygen Conversion Existing oxygen combustion system produce localised overheating and as a result increased dross. Low momentum QUADRAFLO SWEEP© Burners with full automatic controls are installed. The roof mounted QUADRAFLO SWEEP© burners utilise a greater area of the furnace for melting with a very even heat and no localised overheating, as the flame is not fixed in one spot. The charge pile melts down evenly with less oxidation. Post combustion, to compensate for hydrocarbon gases from burned off coating etc., can be achieved with the automatic control system. In addition to the production increase, a corresponding increases in energy efficiency and metal recovery can be seen. • Energy saving 15-25% • Dross reduction: 20-40% • Melt rate increase: 20-40% Conclusion Today, focusing on environmental friendly production and products, such as lighter products in vehicles and air crafts, we at Hotwork International facing these challenges with our oxy-fuel aluminium Melting Technology. With lower emissions and higher efficiency, the QUADRAFLO SWEEP© burner assists customers in reducing their CO2 footprint, getting credits and Aluminium International Today
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ENERGY EFFICIENCY 67
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Fig 7. (left) QUADRAFLO SWEEP© burner hot face
Fig 9. (right) QUADRAFLO SWEEP© burner typical skid on roof installation
Fig 8. QUADRAFLO SWEEP© typical flame
improving production all at the same time. We continuously work on further improvements, based on client’s requests and feedback. Recent improvements to the system make installation and
operation much more simple and cost effective. During the past few years, these improvements and upgrades have resulted in improved performance, longer part life and increased safety. �
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68 READY FOR INDUSTRY 4.0
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New generation of Novelis PAE “hands free” casting The development of hands free automatic DC casting started at Novelis PAE more than 40 years ago, in the 70’s. It was mainly driven by safety issues such as keeping the operator away from the pit and protecting him from the different risks, in particular from the risk of explosion. In the 80’s, major aluminium plants in Europe such as Aluminium Dunkerque, AluNorf, Constellium Neuf Brisach, Hydro Neuss, Hydro Hamburg, implemented the AUTOPAK® system, thus enabling safe hands-free casting. It was the origin of the first automatic metal level control system for DC casting: Novelis PAE now proposes a further step with AUTOPAK® Metal Drive System, a flexible and reliable system based on new, fully digital capacitance sensors and actuators, dedicated to revamping and new automation projects, paving the way to Industry 4.0 equipment. The choice of a reliable CAN Bus solution for low foot print plug and cast solution A weak point of some existing casting launders is the number of embarked electrical devices. The necessary cables and connectors to control this equipment are located directly on the launder in a hot and harsh environment. In some cases, a control cabinet with control
Fig 1. Network architecture
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modules is located outside the casting pit: This implies the use of sensitive signal cables, with a risk of damages during the handling of the casting launder. To limit this phenomenon, the control cabinet can be embarked directly on the casting launder. This last solution remains space consuming, and is often complicated to implement. The new metal level control system proposed by Novelis PAE is much more compact: The control modules of the sensors and actuators are directly embedded inside the sensor or actuator enclosures. Only standard CAN bus and standard power supply cables are used to communicate and control the sensors and actuators from the plc system. Industry 4.0 ready, flexible interface for future evolutions By using the CAN bus network, sensors and actuators are set up and controlled automatically from the main control interface. This access is also given on line through a Web Server and a dedicated software, called AUTOPAK® Interface, to check and set all data through an Internet link. A specific network hub is available to make the interface between the CAN bus used on the casting launder and the customer standard networks
communication protocol such as Ethernet, Profinet or Ethernet I/P, to name a few (Fig. 1). All the internal parameters can be collected and sent back immediately to the main supervision system. The data collection of each parameter in a large database makes a detailed and interactive data analysis possible. It leads to a potential predictive maintenance of the components and finally extended lifetime of the sensors or flow-controller. It leaves many future possibilities of improving the process by automatically analysing this data. Visual management If a camera system can be added on the pit to help the operator in the cabin to visualise the pit, a simple and robust programmable led bar graph (Fig. 2) is integrated on each flow controller and sensor. Configured according to the needs of each cast house, it helps the operator to have an instantaneous idea of the sensor status and casting stage. An alarm can also be visualised easily not only inside the control cabin, but also all around the pit during maintenance works. The new AUTOPAK® Metal Drive System was recently implemented at the Alunorf cast house in Germany. An automatic metal level regulation system was installed on an existing casting pit to modernise and replace a manual system. The new generation of sensors and actuators have been successfully tested in real and industrial conditions. �
Fig 2. CS-F240 Capacitance Sensor
Aluminium International Today
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FOIL 69
www.aluminiumtoday.com Achenbach SUPERSTACK® II Rolling Oil Filtration System
Achenbach OPTIMILL® Foil Rolling Mill
Future concepts in battery foil production New Greenfield aluminium foil production plant in Hungary ACHENBACH BUSCHHÜTTEN, specialist and world market leader for aluminium foil rolling mills and foil slitting machines was ordered by LOTTE ALUMINIUM, subsidiary of the multinational LOTTE group which is the fifth-largest company in South Korea, to establish a new Greenfield production plant in Hungary. There, thinnest aluminium foils as a sophisticated carrier material for rechargeable batteries are produced highly productive with Achenbach machinery in the near future. In the first expansion stage the scope of supply and performance comprise three OPTIMILL Foil Rolling Mills automated with OPTIROLL Control Systems and each run with a SUPERSTACK Rolling Oil Microfiltration System. A high efficient AIRPURE system ensures the exhaust air purification of the rolling production for both, environment protection and rolling oil recovery. The processing of the primary material for the battery cell production is made by two SepaSlit Aluminium Foil Separators slitting the sensitive battery foil highly efficient. By comparison, the production per year is sufficient to produce 500,000 pure e-cars or correspondingly more hybrid cars. This visionary major Greenfield investment is the first new aluminium foil production plant of this size in Europe for decades. In the run-up of the order placement it was Achenbach who consultatively supported the customer concerning the planning of the new plant’s layout and technology on the basis of the type and extent of the requested output, always keeping an eye on ensuring an optimal material and work flow concept at a maximal automation level. The trust Lotte Aluminium grants to Achenbach in advance as the supplier for nearly the complete machinery is enormous.
André E. Barten, CEO, says: “Achenbachs integrative solution is benchmark and blueprint of producing battery foils with highest quality assurance and highest productivity. It is an honour to be part of this new era of production in Europe.” Certainly the most modern technology was decisive primarily by placing the order: Regarding engineering, manufacturing and pre-assembly to the greatest possible extent, Achenbach machinery is really ‘Made in Germany’. The following synergies between engineering and production on the one hand and between rolling and processing on the other hand can thus be used for a sustainable client
benefits. Furthermore, the Achenbach OPTILINK® technology brings out big data applications with high customer benefit. This includes in particular the cloud-based IoT platform for the overall machinery networking of the individual value chain levels. This platform allows the operator to control and operate his current production concerning both, quantity and quality at anytime and anywhere in the world. Due to its high relevance, OPTLINK enjoys great popularity in the market by now. Concerning the individual machines it is the combination of great expertise and decade-long experience in rolling mill building for the production of thinnest
André E. Barten, President & CEO, ACHENBACH BUSCHHÜTTEN and Cho Hyuncheol, President & CEO, LOTTE ALUMINIUM
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70 FOIL
www.aluminiumtoday.com Achenbach AIRPURE® Exhaust Air Purification System
Achenbach SepaSlit® Separator
foils. Only one of lots of highly complex technology components is the Achenbach OPTIROLL® Automation Technology with its modules MillModelling Process Simulation, MillView Visualisation, MillGauge Strip Thickness Control, MillFlat Strip Flatness Control, MillDrive Drive Control and MillMove Squence Control. The OPTIPURE Media Systems is of big importance for the economically and ecologically efficient exhaust air purification, rolling oil microfiltration and rectification, all working in a closed loop principle together; here too, Achenbach is the state-of-the-art world leader. Finally, it is the positive experience with Achenbach machinery – own or thirdparty – being confidence-building and the personal relations which – as in this case – grew over decades. Geographically South Korea belongs to those countries
where Achenbach has particulary significant references. For example, Lotte Aluminium bought its first foil rolling mill for its Ansan plant 25 years ago and already before the investment decision for a new production plant in Hungary Lotte Aluminium ordered another Achenbach OPTIMILL® Foil Rolling mill in 2018 going into operation in 2020 in South Korea. It will increase the local capacity of thin and ultra-thin rolled aluminium foil significantly. Furthermore, this foil rolling mill will be able to produce single-layer rolled battery foil as well as double-layer rolled aluminium foil highly productive and in best quality. Furthermore, one new NovaSlit® slitting machine complements the increase in production in South Korea for high-quality foil slitting. Technical highlights characterising the new plant of Lotte Aluminium in
Hungary are the integrated, digital and modular designed automation system OPTIROLL®i3, the Achenbach DVC Backup Roll System with dynamically variable adaption of the crown, the Achenbach UniSpray® Coolant Distribution System with adaptive nozzle valve header, the hoseless roiling oil supply including hot spray system for roll cooling for optimum heat discharge, the highly efficient Achenbach UniDry® Rolling Oil Blow-off System for evenly dry strip surfaces, the automatic foil feeding system Achenbach FFS or the ironing roller system of Achenbach for highest rewinding speeds. Examples for technical highlights within the slitting machines are: A hydropneumatic, weight-balanced pressure system with innovative double
The enormous demand for efficient lithium-ion batteries result on the one hand from the mega trend electric mobility: By now, electric cars resp. hybrid vehicles emancipated from being niche vehicles for idealists. The number of registrations increase rapidly worldwide in all developed countries and its advantages become clearer and clearer to the consumers. A respective charging station infrastructure and the people’s willingness to contribute to climate protection especially in city traffic are basic preconditions. On the other hand so-called ‘power-tools’ of daily life such as vacuum cleaners, leaf blowers, cleaning robots or battery hammer drills with efficient lithium-ion batteries and also industrial applications as in operating forklifts or drones are used more and more.
The new NovaSlit® in preassembly phase for LOTTE ALUMINIUM in Korea
diaphragm cylinder, a new cutting dust suction system in combination with an optimised scissors cut for thinnest aluminium foil, high ambition to keep the machine clean from dust and oil, machine utilisation for the single-layer and doublelayer foil production without additional set-up times. To sum it up, the new aluminium production plant in Hungary focussing on battery foils has the potential to become strategically, conceptually as well as technically down to details a ‘lighthouse project’ finding world-wide attention. �
Aluminium International Today
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STRIP PROCESSING 71
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REDEX Group opens technical centre for strip processing solutions After taking over UNGERER GmbH in 2017, REDEX Group has acquired strategic patents from BWG GmbH.
As a result, REDEX Group is now able to offer the largest portfolio of Metal Strip Processing solutions, from foil to heavy gage coils. With the aim to develop new technologies and support metal strip producers worldwide, REDEX Group has strengthened its R&D by opening an Engineering Center in Duisburg. Modern production and assembly facilities in France (Ferrieres) and Germany
(Pforzheim), as well as service centers in China (Shanghai) and the USA (NewJersey) allows REDEX Group to offer full service, from engineering to key equipments through complete strip Processing lines, and from automation or measuring & control systems, to spare parts and training. Portfolio of Metal Strip Processing solutions from REDEX Group includes consulting service, engineering and line
modernization, complete process lines (heat treatment, coating, cleaning...), finishing lines (Tension leveling, slitting, cut to length), in-line flatness measurement and closed loop control systems, as well as key equipment (skin-pass mills, flying shears, Stacking units, edge trimmer...) and toolings (20-high mill backing Assemblies, leveler cassettes and working rolls...). ďż˝
REDEX Group is a 70 year old family owned European group with facilities in Europe, USA, China and India. With more than 100 engineers and 450 employees worldwide, a portfolio of 40 patents, REDEX Group is an innovative company with a global footprint and strong expertise on key industrial processes. http://www.redex-group.com
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72 SMELTING SOLUTIONS
OxyCIRâ&#x201E;˘ offers new lease of life for long-suffering carbon anodes Aluminium engineering firm CIR Technologies has developed a ground-breaking sealant system for use at smelters that forms a white coating over pre-baked carbon anodes to extend their lifespan within aluminium electrolysis cells. Vice-president and General Manager Ghislain Gonthier, P.Eng., PMP, shares how the OxyCIR sealant works and who can benefit. Giant problem, simple solution A recurring challenge in operating a safe, efficient, productive, profitable and environmentally responsible aluminium smelter operation is the severe air burn oxidization of carbon anodes that takes place within the electrolysis cells, one of the factors governing the replacement frequency of corroded anodes at a great cost to companies in time, expense and environmental impact. To solve this problem, CIR Technologies created the OxyCIR sealant to protect and extend the life of the pre-baked anodes. While the rate of corrosion and frequency of anode replacement is variable depending on factors such as May/June 2020
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the intrinsic air reactivity of the anode, it is well known that the excess carbon consumption caused by air reactivity corresponds to up to 20% of the gross anode consumption. Yet even when exposed to the harsh conditions within the aluminium electrolysis cells, the OxyCIR coating system effectively decreases severe oxidation. Specifically, the system acts as a physical barrier between the carbon and the surrounding air, keeping oxygen away from the carbon surface thereby achieving the inhibition of the oxidation process of the exposed areas. With an OxyCIR sealant, the isolation of the anode surface from the harsh environment is achieved so
the carbon mass remains better preserved during the whole anode cycle, from insertion into the cell and up until its butt has completely cooled down outside of the cell. The sealed anode surface highly reduces its permeability and the reaction between the air and the carbon is allbut avoided. At the same time, since the anode maintains its original shape, the sealed anode area available for the flow of electrical current is increased so more aluminum can be produced per kilo of carbon, which corresponds to a decrease in the net carbon consumption. Perfecting the product and process The thin coating of OxyCIR is applied to Aluminium International Today
11/05/2020 12:07:34
74 SMELTING SOLUTIONS
the anodes in the same way other sealants can be simply painted or sprayed on to a surface. Perfecting the compounds that make up the sealant took years of research and testing in the CIR lab and at company smelters. OxyCIR is therefore formulated to be perfectly compatible with the bath and all the elements involved in the aluminium electrolysis process. No undesirable elements will be added to the bath when using the system. The impermeable feature of the OxyCIR-coated anode can also greatly minimise the production of carbon dust generated as an effect of the corrosion taking place during oxidisation in the cell. This reduction of dust will then turn into less carbon contamination in the bath, hence a reduction in the resistivity of the bath.
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being recycled without being coated. Since the spent anodes for recycling have a greater size and quality, the requirement for new prebaked anodes will decrease as will the raw material requirement, leading to lower future production costs. OxyCIR success and more OxyCIR is one of three key innovations
developed by Canadian-based CIR Technologies and available to smelters .. Together with his research, laboratory and engineering team, company President Claude Allaire, P.Eng., PhD, also invented: Refraseal™, a refractory sealant for cell liners (learn more in Aluminium International Today magazine, March/ April 2020 Edition, Page 7) and; Plastic Patch™, a non-toxic material used to caulk expansion joints in anode baking furnaces, replacing traditional ceramic fibres (learn more at CIRtechnologies.ca). Factory trials and testing currently underway all produced the same results to-date: success. And while very specific details remain private at this time to respect client agreements and relationships, rest assured that consulting services include a complete and customised experience with extensive data discussed and deployed. Across the globe, CIR Technologies and the companies who take action and benefit from product innovations, can help to build a bright future for the global aluminium industry and together, can help to bring a hundred-year-old smelter process into the 21st Century and beyond. �
How OxyCIR benefits spent anodes An added benefit of OxyCIR is that even when the anode has eventually completed its lifecycle, the seal remains as an external protection. And, when the anode butts are returned from the smelters for stripping, they will retain a bigger size than those May/June 2020
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Aluminium International Today
11/05/2020 12:07:40
浇铸厂技术 75
中国展位
去年的中国铝展的参观者可能会清楚地记得“铝伴侣” ，它是代表铝 业专家 MQP 坚定承诺提高行业标准和可能是世界上最可持续的材 料之一的质量的标志性符号。 今年，她回到 11K71 号展位，MQP 将展 示在其开创性的晶粒细化剂 Optifine 的持续开发中所取得的最新突 破性成果……
铝伴侣归来 - MQP 将展示 里程碑性的细化剂 游戏规则改变者
随着气候变化议程的日渐升温，铝已成 为最环保的材料之一，因此，浇铸厂必 须迅速提高具有出色的内部和表面质 量的板坯和钢坯的产量，以生产从铝制 车身顶板、饰条、飞机翼片及外壳到轻 质包层在内的各种产品。 然而，尽管市场呈指数级增长，但晶 粒细化的工艺依旧存在诸多亟待改进 之处，因此，浇铸厂仍依赖质量参差不 齐的晶粒细化剂，并最终在满足客户 要求的所需内部和表面质量标准方面
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存在问题 。考虑到这一普遍存在的问 题，MQP 开发了致力于成为市场上最高 效的晶粒细化剂之一的 Optifine。 这款突破性的创新产品于 2010 年首 次投入正常生产中，可实现避免铸锭开 裂所需的晶粒细化水平，其添加率比标 准的 TiBAl 晶粒细化剂最多可降低 80 ％，从而在各种铝合金合成物中，均可 以提高质量并降低 50％ 以上的运营成 本。 Optifine 由 MQP 的新合作伙伴 STNM 在最先进的设备上生产，目
前，Optifinee 在全球 34 个主要浇铸厂 每年超过 300 万吨的铝合金生产中取 得了卓越的成果，并且其在全球（尤其 是中国和亚洲）的市场份额不断增长。 “Optimine 的开发归功于我们自 身在铝行业积累的经验以及关于浇铸 厂在处理不时发生的一系列与晶粒细 化相关的问题时遇到的日常难题的研 究成果，例如开裂、大晶粒尺寸以及高 发生率的内部夹杂物和表面缺陷等问 题，这些问题通常会导致产品报废或性 能下降并最终导致浪费。 ”MQP 董事长 2020 年 5 月/6 月
07/05/2020 11:34:55
76 浇铸厂技术
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14
六角板材
LiMCA 图
12
LiMCA 读数
10 8 6 4 2
0
存量的同时减少卷材更换。
过滤器使用寿命 <100T <800T <1700T <2400T <3100T >3100T
Opticast Optifine 通常与 MQP 的 Opticast 系统 结合应用于浇铸厂，该系统采用独特的 技术和方法，用于晶粒细化的在线控制 和优化。为提高质量并降低成本，由斯 德哥尔摩大学的 Lennart Backerud 和 Rein Vainik 设计的 Opticast 系统已成 功地应用于全世界铝厂的日常生产中。 John Courtenay 表示。 “使用 Optifine 高效中间合金，并通 “ 随 着 公 司 对 更 高 质 量 的 产 品 的 需 过我们的 Opticast 系统密切监控晶粒 求以及 MQP 的积极投入，我们开发出 细化工艺，实际上消除了铸锭和钢坯开 了独特的高效晶粒细化剂 Optifine。 裂的风险，”John 表示。 如今，我们通过遍布铝市场各个地区（ “为浇铸厂提供全面的技术支持是我 从澳大拉西亚到南非，从欧洲到美洲） 们工作的关键举措，从而确保可以万无 的区域销售经理、顾问和分销商网络运 一失且始终如一地实现最佳 Optifine 营。由于认识到日益增长的中国市场的 添加率，以最大程度地节省成本。 ” 巨大潜力，我们于 2018 年成立了 MQP 重要的是，在 Rein Vainik 博士的领导 中国公司以率先进入市场。 下，在我们位于瑞典斯德哥尔摩附近的 实验室设施中，Opticast 技术也以 MQP 结果 的广泛测试和质量控制体系为核心。我 合理展示 Optifine 的创新性和有效性， 们的指导理念是，应完全独立于制造过 如果浇铸厂完全转用 Optifine，成本将 程进行测试，以确保始终保持 Optifine 如下所示： 高效率的黄金标准。 通常，年产量为 30 万吨的大型冶炼厂 或熔铸厂将采购 300 吨标准晶粒细化 未来增长 剂，其成本为 1,170,000 美元。 在增长方面，与 STNM 新的合作伙伴关 当转用 Optifine 时，我们保证将降低 系确实无疑成为一个转折点。 一半成本，即节省 585,000 美元！ 经过 5 年的试水，Optifine 的销量在 除此之外，晶粒细化剂的用量减少了 2016 年真正开始增长，与 2015 年相比 70％，这意味着可能导致铸造缺陷的潜 增长了 67％，吨数增加至近 1,000 吨， 在颗粒数量降低了 70％。 最近在一家经 这相当于 3,000 吨标准晶粒细化剂或中 常使用 Optifine 的大型浇铸厂，我们利 国以外市场的 10％。 用 LiMCA 的研究结果可以证明这一点。 凭借如此大幅的增长，MQP 得出了需 对于浇铸厂的员工来说，Optifine 同 新建生产工厂的结论，并与 STNM（河北 样能带来好处，他们每周不得不在减少 四通新型金属材料股份有限公司）签署 浇铸厂周围的运输并降低仓库中的库 了协议。 STNM 拥有 MQP 70％ 的股份， Optifine 车间
目前在位于保定的工厂生产 Optifine， 该厂每年可以生产 16,000 吨晶粒细化 剂，到今年晚些时候，新工厂扩建投产 后将增至 38,000 吨。 John 表示，与 STNM 的合作伙伴关 系意味着 MQP 已经为在不久的将来将 新品种的 Optifine 晶粒细化剂推向市 场做好了准备。 “STNM 是一个理想的合作伙伴，我 们将受益于在现代化、高产能的生产工 厂中生产的 Optifine，该工厂计划进行 扩建，并准备在研发、新产品推出、完善 的全球库存设施以及卓越的质量控制 方面投入大量资金，”他说。
开拓性的研究
MQP 目前正在布鲁内尔大学进行一项 为期两年的重点研究项目，以寻求进一 步提高 Optifine 效率的方法。 我们正在使用高分辨率透射电子显微 镜 (HRTEM) 进行这项研究。 全世界仅有 四家此类机构，MQP 拥有独一无二的机 会，旨在进行前所未有的研究。 “理论表明，只有在 TiB2 颗粒表面沉 积一层 Al3Ti 之后，才能进行有效的晶 粒细化，”John 表示。 “使用这种最先进的电子显微镜，可 以在原子层面上研究 TiB2 颗粒的表面 结构，从而揭示 Al3Ti 层的真实本质。 ” “我们可以识别所涉及的原子层的数 量，因此可以识别该层的厚度。”该设备 还可以识别这些原子的构成，这可能有 助于了解有关锆等过渡元素的中毒机 理。通过研究这一课题，我们希望能够 找到解决中毒问题的方法。 “作为提升熔体质量的领导者，我们 致力于创新以使整个行业受益，”他补 充说。�
有关更多信息，请访问 www.mqpltd.com。 您也可以在 LinkedIn 和 Twitter 上关注 MQP 的最新动向。
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MQP-downgrade.indd 2
Aluminium International Today
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能源效率 77
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更少的浮渣和更高的能效
作者 Benjamin Köster*
与传统的空气燃料和含氧燃料系统 相比，QUADRAFLO SWEEP© 铝熔炼 系统 65 个以上的装置表现出多方面 的优势（图 1）： • 已证明节能 15-60% • 在典型情况下，可减少热浮渣 约 20％ 及以上 • 缩短循环时间并提高熔化能力 • 降低 Noxx 并减少CO2 排放量 • 熔池覆盖率高， 无需安装较多燃烧器 • 延长熔炉耐火材料使用寿命 • 改善控制
图 1.两种 QUADRAFLO SWEEP© 燃烧器火焰图谱
QUADRAFLO SWEEP© 铝熔炼系统 渣 形 成 量，从 而 实 现 了 最 佳 的 经 济 Hotwork International 持有 是一种基于氧气的燃烧系统。 当然，氧 效益。 气燃烧器通常比冷空气或预热空气燃 QUADRAFLO SWEEP© 技术的许可证， 烧器具有更高的能源效率，但是在应 从而成为该行业与 XOTHERMIC Inc. 用氧气燃烧技术时，如何大幅减少浮 合作应用该技术的直接合作伙伴。 渣呢？ 铝是地壳中含量第三丰富的材料。 设计理念 铝金属具有很强的氧亲和性，由于这 我们以二次铝反射炉作为进入铝市场 种亲和性，铝在自然界中不会作为金 的切入点。这是全球范围内用于一次和 属自然出现。 二次铝熔炼的传统熔炉。该熔炉主要由 因此，您可能会问，如何以及为什么 砌有耐火材料的钢箱（其能量来自燃烧 可以将纯氧与天然气一起使用来熔化 系统）、排气口、冷金属进料口组成，在 铝而不会增加氧化程度。这是通过在 某些情况下还包括单独的浮渣口和熔 铝熔炼或保温炉中合理应用氧气燃烧 融金属出料口 。此设计有多种配置可 器技术来实现的。 选，但是所有设计的基本工作原理都是 XOTHERMIC Inc. 开发了 相同的。来自燃烧系统的热源以足够的 QUADRAFLO Sweep© 铝熔炼系 力将热量传递到冷金属中，以使金属保 统。 XOTHERMIC 并未应用用于玻 持热量直至达到熔点（平均为 657°C）。 璃、钢、铜等其他高温应用或其他相 在此过程中，最理想的是在进行热传递 关 领 域 的 燃 烧 器，而 是 研 究 了 铝 熔 的同时尽量减少氧化作用。在生产周期 体应用并通过现场试验开发了最优 的最终过程中，需要进一步加热以提供 设计。 QUADRAFLO SWEEP© 铝熔 足够的能量，从而将铝保持在熔融状态 技 术 提 供 了 最 高 的 能 效 、最 低 的 浮 （平均为 750°C）。
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哪些因素会导致过度氧化？所有铝 均由于与大气中的氧气相互作用而形 成氧化层。这种氧化程度取决于金属 的老化及老化状况，例如油漆、搪瓷或 其他类型的钝化作用。在大多数情况 下，这是次要因素。 所谓的氧化是在熔 炼过程中作为燃烧过程的副产物而产 生的氧化。 通常，由于冷料暴露于过高 的热量和氧气浓度而产生过度氧化。 如 何 防 止 过 度 氧 化 ？这 是 QUADRAFLO SWEEP©铝系统设计理 念的主要前提。我们设计了一种可以 将装料上产生的过热点降至最低的燃 烧器系统。这是通过使用移过或扫过 装料的扁平鱼尾形火焰而实现的。另 一项要求是燃烧器速度的动量应较 低，以尽量减少对熔融金属熔池的干 扰。 火焰移动的最大范围为 45 度。 在 数秒钟的时间内，移动火焰即可将热 量传递到比固定火焰大得多的区域。 固定火焰燃烧器试图将装料区域加热 至过高温度，以将热量传递到灌注桩 的其他部分。这会产生明显的热点并
HOTWORK International AG 首席执行官 www.hotwork.ag
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78 能源效率
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形成更多的浮渣。 还提供了对氧气/燃 料比保持极严格公差的流量控制系 统。 即使用空气会产生更多的浮渣，但 由于要为氧气付费，因此您不希望浪 费氧气，这一点至关重要。 必须了解的 是，无论氧源、空气还是纯氧，多余氧 仍然保持约百分之几的相同比例。由 于使用纯氧，因此这并不意味着浮渣 会增多。如果温度过高，则影响更大。 实际上，如果在 657 摄氏度的熔融铝 熔池上覆盖一层纯氧且无火焰，则结 果表明，在氧气含量为 21％ 的空气覆 盖层上，浮渣几乎没有或根本未增加。 应用与经验 如前所述，由于具有多种反射及其他熔 炉设计，因此需要针对特定的熔炉设计 与应用作出独特的个性化设计变更。
图 2.燃烧炉体和典型安装
倾斜反射 蓄热到氧气的转化
图 3.采用 QADRAFLO SWEEP 燃烧器的反射炉 ©
49 容积吨倾斜反射
由于除去了氮气，氧气燃烧器产生的废 气比空气燃烧器约减少 60-80％。 这样 可以提高能效、降低 NOX 的产生并减少 排放到大气之前要清洁的气体。与蓄热 式燃烧器相比，其能效可提高 50％。 最
空气炉火
氧燃烧器的竞争对手
Quadraflo 扫过
燃烧器位置
端墙
端墙
顶部
每天循环数
1.8
2.2
周期时间（小时）
13
11
熔化能力 mt/d
42.5
50.2
能力约提高
18.2
66
平均浮渣
8%
熔化速度 mt/h
天然气需求 NM/mt
每年节省的金属 mt
1.8
120 -
2.1 70
8% -
8 3
70.5 2.9 55
7%
225.6
图 4.比较表
图 5.采用 QUADRAFLO SWEEP© 燃烧器的 反射炉
2020 年 5 月/6 月
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图 6.采用 QUADRAFLO SWEEP© 燃烧器的塔式 熔炼炉
重要的是，可以显著降低炉膛压力，从 而避免了高火期间的火焰，以免损坏耐 火材料和炉门等。炉膛通常与空气燃料 燃烧器一样在较低的温度下运行。各种 讨论已证明： • 节能 35-40% • 减少浮渣：20-40% • 提高熔化速度：20-40%
氧气到氧气的转化
现有的氧燃烧系统会产生局部过热，因 此会增加浮渣。已安装具有全自动控制 装置的低动量 QUADRAFLO SWEEP© 燃烧器。由于火焰未固定在同一点上， 顶部安装式 QUADRAFLO SWEEP© 燃 烧器能够利用较大的熔炉面积进行熔 化，同时热量极为均匀且无局部过热。 装料桩熔化均匀，氧化较少。通过自动 控制系统可以实现二次燃烧，以补偿燃 尽的涂层等产生的碳氢化合物气体。除 了提高产量外，还相应提高了能源效率 和金属回收率。 • 节能 15-25% • 减少浮渣：20-40% • 提高熔化速度：20-40%
结论
今天，我们专注于环保型生产和产品，例
如车辆和飞机的轻量化产品，Hotwork International 正面临与氧燃料铝熔炼 技术相关的挑战。
QUADRAFLO SWEEP© 燃烧器具有 更低的排放量和更高的效率，有助于 客户减少 CO2 排放量，从而获得信誉 并同时提高产量。 Aluminium International Today
12/05/2020 09:35:25
能源效率 79 00
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图 7.（左） QUADRAFLO SWEEP© 燃烧器加 热面
图 9.（右） QUADRAFLO SWEEP© 燃烧器安装在 顶部时的典型滑轨
图 8.QUADRAFLO SWEEP© 典型火焰
我们会根据客户的要求和反馈持续 致力于进一步的改进。该系统的最新 改进使得安装和操作更加简单且更具
成本效益。 在过去几年间，这些改进和 升级带来了更强的性能、更长的零件 寿命和更高的安全性。 ■
Quadraflo© Sweep Aluminum Melting System 铝 熔 系 统
熔铝系统 经过验证节能率为15%-60% 热渣减少约20% 低氮氧化物/减少二氧化碳排放 高熔化面积 客户自定义配置
您可以通过下面的电子邮 件和网站与我们联系。
www.hotwork.ag contact@hotwork.ag
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2020 年 5 月/6 月
12/05/2020 09:35:30
80 准备迎接工业 4.0
Novelis PAE 新一代的 “免手动”铸造 Novelis PAE 在 40 多年前的 70 年代即着手开发免手动的自动 DC 铸 造 。安 全 问 题 是 促 进 开 发 的 主 要 驱 动 力 ，例 如 避 免 操 作 员 接 近 铸坑并保护操作员免受各种危险 （尤其是爆炸危险）的伤害。 80 年代，Aluminium Dunkerque、 AluNorf、Constellium Neuf Brisach、 Hydro Neuss、Hydro Hamburg 等欧洲 主要的铝厂均实施了 AUTOPAK® 系统， 从而实现了安全的免手动铸造。 这是首个用于 DC 铸造的自动金属液 面控制系统的由来：Novelis PAE 目前提 出了采用旨在改造和新建自动化项目 的 AUTOPAK® 金属驱动系统的进一步 建议，这是一套基于新型全数字电容传 感器和执行器的灵活而可靠的系统，从 而为转向工业 4.0 设备铺平了道路。
选择可靠的 CAN 总线解决方案， 以实现低占用空间填塞和浇铸解 决方案 现有的一些浇铸流槽的弱点是 所搭载电气元件的数量。在炎热
和恶劣的环境中，控制本设备所 必需的电缆和连接器直接位于 流槽上。在某些情况下，带有控 制模块的控制柜位于浇铸坑之 外：这意味着需使用敏感的信号 电缆，因此在操作浇铸流槽时存 在损坏的危险。为了减少这种现 象，可以将控制柜直接置于浇铸 流槽上。最后一种解决方案仍然 占用较大空间，并且实施起来通 常复杂重重。 Novelis PAE 建议的新型金属液面控 制系统则更为紧凑：传感器和执行器的 控制模块直接嵌入传感器或执行器的 外壳内。 仅使用标准的 CAN 总线和标 准的电源电缆通过 PLC 系统控制传感 器和执行器并与之进行通信。
面向工业 4.0 的灵活接口，可应 对未来发展
通过使用 CAN 总线网络，可以从主控 界面自动设置并控制传感器和执行 器。 还可以通过 Web 服务器和名为 AUTOPAK® Interface 的专用软件在线
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授予此访问的权限，以通过网络链路检 查并设置所有数据。 一台专门的网络集线器可用于在浇 铸流槽上使用的 CAN 总线与客户标准 网络通信协议（例如 Ethernet、Profinet 或 Ethernet I/P，仅举几例）之间建立连 接（图 1）。 可以收集所有内部参数并将其立即 发送回主监控系统。通过采集大型数据 库中每个参数的数据，可以进行详细的 交互式数据分析。因此，可以对组件进 行潜在的预见性维护，并最终延长传感 器或流量控制器的使用寿命。通过自动 分析这些数据，为未来改进工艺保留了 多种可能性。
可视化管理 如果可以在浇铸坑上加装摄像 头系统以帮助控制室中的操作 员实现浇铸坑的可视化，则每个 流量控制器和传感器上均应集 成一个简单而强大的可编程 LED 条形图（图 2）。 由于可以根据每 个铸造车间的需求进行配置，因 此有助于操作员即时了解传感 器状态和铸造阶段。在执行维护 作业期间，不仅在控制室内而且 在整个浇铸坑周围，均可以轻松 查看报警。
最近，在德国的 Alunorf 铸造车间实 施了新型 AUTOPAK® 金属驱动系统。 在 现有的浇铸坑上安装了自动金属液面 调节系统，以现代化并取代手动系统。 已经在实际和工业条件下成功测试了 新一代传感器和执行器。�
图 1.网络架构
2020 年 5 月/6 月
AMDS - for chinese-downgrade.zh-CN 27 april.indd 1
图 2.CS-F240 电容传感器
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箔材 81
www.aluminiumtoday.com Achenbach SUPERSTACK® II 轧制润滑油微滤系统
Achenbach OPTIMILL® 箔材轧机
蓄电池箔材生产中的未来概念 新建的匈牙利 Greenfield 铝箔生产工厂 铝箔轧机和箔材分切机的专家 及全球市场领导者 ACHENBACH BUSCHHÜTTEN 受韩国第五大公 司 LOTTE 跨国集团的子公司 LOTTE ALUMINIUM 的委托，在匈牙利新建 了 Greenfield 生产工厂。 在不久的将 来，即可在该工厂使用 Achenbach 机 械设备高效地生产作为可充电电池的 先进载体材料的最薄铝箔。在首个扩 张阶段，供货和产能范围包括三台通 过 OPTIROLL 控制系统实现自动化的 OPTIMILL 铝箔轧机，并且每台均配有 SUPERSTACK 轧制润滑油微滤系统。 高 效的 AIRPURE 系统可确保轧制生产中 的废气净化，从而既环保又可回收轧制 润滑油。加工用于蓄电池单元生产的主 要材料时，是通过两台 SepaSlit 铝箔分 卷机高效地分切敏感的蓄电池箔材而 完成的。相比之下，每年的产量足以生 产 500,000 辆纯电动汽车或相应更多 的混合动力汽车。 这项富有远见的重大 Greenfield 投 资是数十年来欧洲首家如此规模的新 铝箔生产工厂。由于始终关注以最大 的自动化水平确保最佳的物料和工作 流程概念，因此在订购的准备阶段，正 是 Achenbach 在客户要求的产出类型 和范围的基础上，就新工厂的布局和技 术的规划向客户提供咨询服务。作为 几乎整套机械供应商的 Achenbach 事 先就赢得了 Lotte Aluminium 极大的 信任。 首席执行官 André E. Barten 表 示： “Achenbachs 总体解决方案是生产
蓄电池箔材的标杆和蓝图，具有最高的 质量保证和最高的生产效率。我们很荣 幸能够加入欧洲这一新的生产纪元。 ” 当然，即使是最先进的技术，只有下 达订单后才能发挥其决定性的作用：在 涉及最大程度的工程、制造和预装配 方面，Achenbach 机械真正是“德国制 造”。因此，一方面在工程与生产之间， 另一方面在轧制与加工之间的以下协 同效应可为客户带来持续的利益 。此 外，Achenbach OPTILINK® 技术带来 了具有高客户效益的大数据应用。尤其
是，其中包括面向各个价值链级别的整 体机械网络的云计算 IoT 平台。 利用该 平台，操作员可以随时随地控制和操作 现行生产的数量和质量。由于具有高度 相关性，OPTLINK 目前在市场上享有很 高的知名度。 就 单 台 机 器 而 言，它 是 轧 机 制 造 领 域丰富的专业知识与数十年经验相 结 合 的 产 物 ，以 实 现 最 薄 箔 材 的 生 产。 Achenbach OPTIROLL® 自动化技 术只是众多高度复杂的技术组件之 一，其模块包括 MillModelling 工艺
ACHENBACH BUSCHHÜTTEN 总裁兼首席执行官 André E. Barten 与 LOTTE ALUMINIUM 总裁兼首席执行官 Cho Hyuncheol
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82 箔材
www.aluminiumtoday.com Achenbach AIRPURE® 废气净化系统
Achenbach SepaSlit® 分卷机
仿真、MillView 可视化、MillGauge 带 钢厚度控制、MillFlat 带钢平直度控 制、MillDrive 驱动控制和 MillMove 顺 序控制。 OPTIPURE 介质系统对于在经 济上和生态上高效的废气净化、轧制润 滑油微滤和精馏至关重要，所有这些作 业均以闭环原则同步进行；在这一领 域，Achenbach 同样在全球处于领先地 位。 最 后 ，这 是 数 十 年 来 锐 意 进 取 的 Achenbach 机械（自有或第三方）在建 立信任和建立人际关系方面的积极经 验，如本例中的情况。在地理位置上，韩
国属于 Achenbach 尤具重要价值的国 家。 例如，Lotte Aluminium 在 25 年前 就为其 Ansan 工厂购买了第一台箔材 轧机，在决定在匈牙利建立新生产工厂 之前，Lotte Aluminium 已于 2018 年 订购了另一台 Achenbach OPTIMILL® 箔材轧机，并将于 2020 年在韩国投入 运营。这将显著提高薄和超薄轧制铝箔 的本地生产能力。此外，该箔材轧机将 能够以高生产率和最佳品 质生产单层 轧制蓄电池箔材以及双层轧制铝箔。而 且，一台新的 NovaSlit® 分切机填补了 韩国高品质箔材分切的增产空白。
匈牙利 Lotte Aluminium 新工厂的技 术亮点为采用集成化、数字化和模块化 设计的自动化系统 OPTIROLL®i3、具有 动态可变适应凸度的 Achenbach DVC 支撑辊系统、带有自适应喷嘴阀头的 Achenbach UniSpray ® 冷却液分配系 统、可实现最佳散热的无软管轧制润滑 油供应系统（包括用于辊冷却的热喷淋 系统）、用于均匀干燥带钢表面的高效 Achenbach UniDry ®轧制润滑油排放系 统、可实现最高收卷速度的自动箔材进
高效锂离子电池的巨大需求一方面来自于大势所趋的电动汽车：
到目前为止，电动汽车已经成为现实，混合动力汽车从理想主义者的特殊汽车中解放出来。 全球所有发达国家的注册数 量都在迅速增加，其优势对于消费者而言越来越明显。 基本前提是各个充电站的基础设施以及人们为气候保护做出贡献 的意愿，在城市交通中尤为如此。 另一方面，所谓的“电动工具”在日常生活中越来越普遍，如使用高效锂离子电池的吸尘 器、吹叶机、清洁机器人或电锤钻，此外，工业应用的使用也越来越广泛，如操作叉车或无人机。 韩国 LOTTE ALUMINIUM 处于预装配阶段的全新 NovaSlit®
料系统 Achenbach FFS 或 Achenbach 熨压辊系统。分切机的技术亮点示例包 括：具有创新双隔膜气缸的液压气动、 重量平衡的压力系统，新型切割吸尘系 统与优化的交叉切割相结合，可切割最 薄的铝箔，保持机器清洁、无尘、无油脂 的宏伟目标，单层和双层箔生产的机器 利用率高，无需额外的布置时间。 综上所述，专注于蓄电池箔材的匈牙 利新铝生产工厂有可能在战略、理念以 及技术上逐步发展成为全球瞩目的“样 板项目”。�
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84 带材加工
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瑞德克斯集团开设了一个新的技术中心，进 一步增强集团提供金属带材处理方案的能力
在2017年收购了德国恩格勒公司之后，瑞德克斯集团又收购了来自德国BWG公司的战略性专利，这些使 得集团能够提供最完整的金属带材精整解决方案，从箔材到非常厚的卷带。
公司的目标是开发新的技术并 服务全球的金属带材生产商，瑞 德克斯集团强化了其研发能力， 通过一个位于德国Duisburg的工 程团队，该团队由Guyon先生和 Baukloh先生管理。 凭借位于法国（Ferrieres）和德 国（Pforzheim）的现代化生产和 装配车间，,以及位于中国（上海）
和美国（New-Jersey）的服务中 心，瑞德克斯集团能够提供完善 的服务，从工程设计到核心设备， 贯穿完整的带材精整生产线，自 动化到测量系统，备件和培训。 瑞德克斯集团能够提供完 整 的 带 材 精 整 方 案，包 括 咨 询 服 务 ，工 程 设 计 和 生 产 线 自 动 化，完 整 的 处 理 线（热 处 理，
彩 涂，清 洗 … ），精 整 设 备（ 拉 弯 矫 直 机 ，纵 剪 机 组 ，横 切 机 组 ），在 线 板 型 测 量 系 统 ，以 及其他核心设备（平整机，矫直 机，切边机…） ，部件（20辊轧机支 承辊系统，矫直机辊箱，矫直机工 作辊…）。
瑞德克斯集团是一家拥有70年历史的欧洲家族企业，在欧洲，美国，中国和印度设有分公司。 全球拥有超过100名工程师和450名员工，以及40个专利。 瑞德克斯集团是一个具有创新精神的企业，享有遍布全球的足迹并在核心工业加工领域拥有强大的专业技术。 http://www.redex-group.com REDEX中国/ REDEX（上海）维修服务 上海市松江区三浜路388号12栋 邮编201611 联系电话: +86 21 6448 0636 传真: - info@redex-group.com 2020年5月/6月
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合作伙伴关系从未如此重要 «我们随时为您服务»
« 在当前困难时刻，我们的专家团队保持在 全世界为您提供免费的咨询和服务» Bruno Grandjean, CEO REDEX Group
基于在金属带材加工行业超过70年的经验，瑞德克斯集团提供 独一无二的带材处理方案集合 轧制，清洗，彩涂，热处理，拉弯矫直，切边，板型测量， 纵剪，横剪
从自动化工程到提供整条生产线，以及测量和控制系统，精密 部件（如20辊轧机支承辊系统，拉弯矫直机箱，拉矫工作辊）
Group Great achievements start with us
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03/05/2020 11:19:02
86 冶炼解决方案
OxyCIR™ 让长期遭受侵蚀的 碳电极重获新生
铝工程公司 CIR Technologies 开发了一种适用于冶炼厂的突破性密封剂系统，该系统在预焙 碳阳极上形成白色涂层，以延长碳电极在铝电解槽中的使用寿命。 副总裁兼总经理 Ghislain Gonthier（工程学教授，项目管理师）分享了 OxyCIR 密封剂的工作原理以及谁可以受益。 复杂的问题，简单的解决方案
在经营安全、高效、多产、可盈利和环保 铝冶炼厂过程中经常遇到的挑战是发 生在电解槽内部的碳电极的空气燃烧 氧化，该问题是决定受腐蚀阳极更换频 率的因素之一，给公司在时间、费用和 环境影响方面带来了巨大的成本 。为 解决此问题，CIR Technologies 开发出 OxyCIR 密封剂，以保护预焙阳极并延长 其使用寿命。 虽然腐蚀速率和阳极更换频率是变化 不定的，具体取决于诸如阳极的固有空 气反应性之类的因素，但众所周知，由 2020 年 5 月/6 月
CIR english-downgrade.zh-CN.indd 1
空气反应性引起的过度碳消耗占阳极 总消耗量的多达 20%。 即使暴露在铝电 解槽内的恶劣条件下，OxyCIR 涂层系统 也能有效减轻严重的氧化。 具体而言，该系统充当碳与周围空气 之间的物理屏障，将氧气与碳表面隔 离，从而实现了对裸露区域氧化过程的 抑制。 有了 OxyCIR 密封剂，阳极表面与 恶劣环境的隔离得以实现，从而在整个 阳极循环过程中（从插入电解槽开始直 至其对接端在电解槽外部完全冷却）， 碳质得以更好地保存。密封的阳极表面 极大大降低了其渗透性，但完全避免了
空气与碳之间的反应。同时，由于阳极 保持其原始形状，可用于电流流动的密 封阳极面积增加，从而每千克碳可生产 更多的铝，这对应于净碳消耗的减少。
完善产品和工艺
以与其他密封剂简单地涂抹或喷涂到 表面相同的方式，将 OxyCIR 的薄涂层 涂覆于阳极上。 在 CIR 实验室和公司冶 炼厂进行了多年的研究和测试，以完善 构成密封剂的化合物。 OxyCIR 因此而配制为与镀液和铝电 解过程中涉及的所有元素完全兼容。使
Aluminium International Today
11/05/2020 12:09:15
冶炼解决方案 87
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用该系统时，不会向镀液中添加任何不 需要的元素。 OxyCIR 涂层阳极的不可 渗透特性还可以极大地减少因电解槽 内氧化过程中发生的腐蚀而产生的碳 粉尘。粉尘的减少意味着镀液中的碳污 染减少，从而降低镀液的电阻率。
开发并可供冶炼厂使用的三项关键 创新之一。 此外，公司总裁 Claude Allaire（工程学教授，哲学博士）与他 的研究、实验室和工程团队一起发明
了：Refraseal™，一种用于电解槽内衬 的耐高温密封剂（有关更多信息，请参 阅《Aluminum International Today》 杂志，2020 年 3 月/4 月刊，第 7 页）；以 及 Plastic Patch™，一种无毒材料，用于 填塞阳极烘烤炉中的伸缩缝，取代了传 统的陶瓷纤维（有关更多信息，请访问 CIRtechnologies.ca）。 迄今为止，正在进行的工厂试验和测 试均产生了相同的结果：成功。虽然目 前为了尊重客户协议和关系，具体细节 仍然处于保密状态，但请放心，咨询服 务包括完整的和定制的体验，并讨论和 部署大量的数据。 在全球范围内，CIR Technologies 和 采取行动并从产品创新中受益的公司 可携手为全球铝业打造光明的未来，并 将已有 100 年历史的冶炼工艺带入 21 世纪以及更远的将来。 ■
OxyCIR 如何使废阳极受益
OxyCIR 的另一个好处是，即使阳极达 到了其使用寿命，密封仍可作为外部保 护。此外，当从冶炼厂返回阳极对接端 进行汽提时，它们的尺寸将比回收的未 经涂覆的对接端更大。由于用于回收的 废阳极具有更大的尺寸和更高的质量， 因此对新的预焙阳极的需求将随着原 材料需求的减少而减少，从而降低未来 的生产成本。
OxyCIR 的成功及更多
OxyCIR 是加拿大 CIR Technologies Aluminium International Today
CIR english-downgrade.zh-CN.indd 2
2020 年 5 月/6 月
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